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KOMATSU D61EX-24 D61PX-24 BULLDOZER SHOP MANUAL SEN06577-06 – PDF DOWNLOAD
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KOMATSU D61EX-24 D61PX-24 BULLDOZER SHOP MANUAL SEN06577-06 – PDF DOWNLOAD
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KOMATSU D61EX-24 D61PX-24 BULLDOZER SHOP MANUAL SEN06577-06 – PDF DOWNLOAD
Language : English
Pages : 2688
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D61EX-24 D61PX-24 BULLDOZER SHOP MANUAL SEN06577-06 – PDF DOWNLOAD
COVER................................................................................................................................................. 1 00 INDEX AND FOREWORD................................................................................................................................ 3 INDEX............................................................................................................................................ 4 ABBREVIATION LIST................................................................................................................................ 21 FOREWORD, SAFETY, BASIC INFORMATION.............................................................................................................. 27 HOW TO READ THE SHOP MANUAL.................................................................................................................. 27 SAFETY NOTICE FOR OPERATION.................................................................................................................. 29 PRECAUTIONS TO PREVENT FIRE.................................................................................................................. 37 ACTIONS IF FIRE OCCURS....................................................................................................................... 39 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS................................................................................................. 40 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................................................................................................ 41 PRECAUTIONS FOR DEF.......................................................................................................................... 42 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING........................................................................................... 42 PRECAUTIONS FOR ADDING................................................................................................................... 42 PRECAUTIONS FOR STORING.................................................................................................................. 42 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE.................................................................................................. 42 THE OTHER PRECAUTIONS.................................................................................................................... 42 STORE AdBlue/DEF............................................................................................................................. 43 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT................................................................................................. 44 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...................................................................................... 47 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................................ 54 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT............................................................................................... 56 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT............................................................................................. 57 PRACTICAL USE OF KOMTRAX..................................................................................................................... 58 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................................ 59 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER.................................................................... 59 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER.................................................................... 60 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER.................................................................... 61 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS................................................................................... 63 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR.................................................................................... 67 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................................ 68 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL.......................................................................... 70 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH.......................................................................... 71 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE..................................................................... 73 HOW TO READ ELECTRICAL WIRE CODE............................................................................................................. 74 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................................ 78 STANDARD TIGHTENING TORQUE TABLE............................................................................................................. 81 CONVERSION TABLE............................................................................................................................. 88 01 SPECIFICATIONS.................................................................................................................................... 93 CONTENTS......................................................................................................................................... 94 ABBREVIATION LIST................................................................................................................................ 95 SPECIFICATIONS................................................................................................................................... 101 SPECIFICATION DRAWING........................................................................................................................ 101 SPECIFICATION DRAWING: D61EX-24.......................................................................................................... 101 SPECIFICATION DRAWING: D61PX-24.......................................................................................................... 103 SPECIFICATIONS............................................................................................................................... 105 SPECIFICATIONS: D61EX-24................................................................................................................. 105 SPECIFICATIONS: D61PX-24................................................................................................................. 110 WEIGHT TABLE................................................................................................................................. 114 WEIGHT TABLE: D61EX-24................................................................................................................... 114 WEIGHT TABLE: D61PX-24................................................................................................................... 116 TABLE OF FUEL, COOLANT, AND LUBRICANTS....................................................................................................... 118 10 STRUCTURE AND FUNCTION............................................................................................................................ 119 CONTENTS......................................................................................................................................... 120 ABBREVIATION LIST................................................................................................................................ 123 UREA SCR SYSTEM.................................................................................................................................. 129 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................................ 129 UREA SCR SYSTEM DIAGRAM...................................................................................................................... 132 FUNCTION OF UREA SCR SYSTEM.................................................................................................................. 133 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................................ 133 INDUCEMENT STRATEGY...................................................................................................................... 135 COMPONENT PARTS OF UREA SCR SYSTEM........................................................................................................... 149 AdBlue/DEF MIXING TUBE................................................................................................................... 149 SCR ASSEMBLY............................................................................................................................. 150 AdBlue/DEF TANK.......................................................................................................................... 152 AdBlue/DEF PUMP.......................................................................................................................... 154 AdBlue/DEF INJECTOR...................................................................................................................... 155 AdBlue/DEF HOSE.......................................................................................................................... 156 AdBlue/DEF TANK HEATING VALVE............................................................................................................ 157 BOOT-UP SYSTEM................................................................................................................................... 158 LAYOUT DRAWING OF BOOT-UP SYSTEM............................................................................................................. 158 SYSTEM OPERATING LAMP SYSTEM................................................................................................................. 159 SYSTEM OPERATING LAMP SYSTEM DIAGRAM..................................................................................................... 159 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM................................................................................................. 159 BATTERY DISCONNECT SWITCH.................................................................................................................... 161 LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH.............................................................................................. 161 FUNCTION OF BATTERY DISCONNECT SWITCH.................................................................................................... 161 ENGINE SYSTEM.................................................................................................................................... 163 LAYOUT DRAWING OF ENGINE SYSTEM.............................................................................................................. 163 ENGINE CONTROL SYSTEM........................................................................................................................ 165 LAYOUT OF ENGINE CONTROL SYSTEM.......................................................................................................... 165 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................................ 167 FUNCTION OF ENGINE CONTROL SYSTEM........................................................................................................ 169 AUTOMATIC IDLE STOP SYSTEM................................................................................................................... 171 AUTOMATIC IDLE STOP SYSTEM DIAGRAM....................................................................................................... 171 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM................................................................................................... 171 COMPONENT PARTS OF ENGINE SYSTEM............................................................................................................. 174 DAMPER................................................................................................................................... 174 VGT...................................................................................................................................... 175 EGR SYSTEM............................................................................................................................... 179 EGR VALVE................................................................................................................................ 181 EGR COOLER............................................................................................................................... 183 KCCV SYSTEM.............................................................................................................................. 185 KCCV VENTILATOR.......................................................................................................................... 187 KDPF..................................................................................................................................... 189 COOLING SYSTEM................................................................................................................................... 193 LAYOUT DRAWING OF COOLING SYSTEM............................................................................................................. 193 SPECIFICATIONS OF COOLING SYSTEM......................................................................................................... 194 COOLING FAN CONTROL SYSTEM................................................................................................................... 195 COOLING FAN CONTROL SYSTEM DIAGRAM....................................................................................................... 195 FUNCTION OF COOLING FAN CONTROL SYSTEM................................................................................................... 196 COMPONENT PARTS OF COOLING SYSTEM............................................................................................................ 198 COOLING FAN MOTOR........................................................................................................................ 198 HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE.................................................................................. 203 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 DECELERATOR AND BRAKE POTENTIOMETER...................................................................................................... 239 HYDRAULIC SYSTEM................................................................................................................................. 241 LAYOUT DRAWING OF HYDRAULIC SYSTEM........................................................................................................... 241 CLSS......................................................................................................................................... 242 STRUCTURE OF CLSS........................................................................................................................ 242 FUNCTION OF CLSS......................................................................................................................... 243 COMPONENT PARTS OF HYDRAULIC SYSTEM.......................................................................................................... 245 HYDRAULIC TANK........................................................................................................................... 245 WORK EQUIPMENT AND COOLING FAN PUMP...................................................................................................... 247 LS VALVE................................................................................................................................. 255 PC VALVE................................................................................................................................. 256 CONTROL VALVE............................................................................................................................ 259 POWER TRAIN SYSTEM............................................................................................................................... 280 LAYOUT DRAWING OF HST SYSTEM................................................................................................................. 280 OPERATION OF HST SYSTEM...................................................................................................................... 281 STEERING AND BRAKE CONTROL SYSTEM............................................................................................................ 283 LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM...................................................................................... 283 FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM............................................................................................ 283 HST CONTROL SYSTEM........................................................................................................................... 285 HST CONTROL SYSTEM DIAGRAM............................................................................................................... 285 GEAR SHIFT CONTROL FUNCTION.............................................................................................................. 286 ENGINE LOW SPEED MATCHING CONTROL FUNCTION............................................................................................... 290 HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION............................................................................................. 290 DECELERATION AND BRAKE CONTROL FUNCTION.................................................................................................. 292 GEAR SHIFT CONTROL FUNCTION BY LOAD...................................................................................................... 293 TURN CONTROL FUNCTION.................................................................................................................... 293 STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION.............................................................................................. 294 PARKING BRAKE CONTROL SYSTEM................................................................................................................. 296 PARKING BRAKE CONTROL SYSTEM DIAGRAM..................................................................................................... 296 FUNCTION OF PARKING BRAKE CONTROL SYSTEM................................................................................................. 297 OPERATION OF PARKING BRAKE CONTROL SYSTEM................................................................................................ 298 COMPONENT PARTS OF POWER TRAIN SYSTEM........................................................................................................ 299 HST PUMP................................................................................................................................. 299 HST CHARGE PUMP.......................................................................................................................... 316 HST MOTOR................................................................................................................................ 317 FINAL DRIVE.............................................................................................................................. 329 ELECTRIC STEERING CONTROL LEVER.......................................................................................................... 333 WORK EQUIPMENT SYSTEM............................................................................................................................ 336 WORK EQUIPMENT CONTROL....................................................................................................................... 336 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM.................................................................................................... 336 FUNCTION OF WORK EQUIPMENT CONTROL....................................................................................................... 337 LAYOUT DRAWING OF FRONT WORK EQUIPMENT....................................................................................................... 339 LAYOUT OF FIXED MULTI-SHANK RIPPER........................................................................................................... 340 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM..................................................................................................... 341 RIPPER PPC VALVE......................................................................................................................... 341 5-PORT VALVE OF EPC AND SOLENOID......................................................................................................... 345 PILOT CIRCUIT ACCUMULATOR................................................................................................................ 351 ANGLE CONTROL EPC VALVE.................................................................................................................. 352 QUICK DROP VALVE......................................................................................................................... 355 PISTON VALVE............................................................................................................................. 357 ELECTRIC BLADE CONTROL LEVER............................................................................................................. 358 UNDERCARRIAGE AND FRAME.......................................................................................................................... 360 MAIN FRAME................................................................................................................................... 360 STRUCTURE OF MAIN FRAME.................................................................................................................. 360 SUSPENSION................................................................................................................................... 361 STRUCTURE OF SUSPENSION.................................................................................................................. 361 SPECIFICATIONS OF SUSPENSION............................................................................................................. 362 FUNCTION OF SUSPENSION................................................................................................................... 363 TRACK FRAME AND IDLER CUSHION................................................................................................................ 364 STRUCTURE OF TRACK FRAME AND IDLER CUSHION............................................................................................... 364 FUNCTION OF TRACK FRAME AND IDLER CUSHION................................................................................................ 365 WORK EQUIPMENT................................................................................................................................... 366 STRUCTURE OF FRONT WORK EQUIPMENT............................................................................................................ 366 STRUCTURE OF FIXED MULTI-SHANK RIPPER........................................................................................................ 367 CAB AND ITS ATTACHMENTS.......................................................................................................................... 368 ROPS CAB..................................................................................................................................... 368 STRUCTURE OF ROPS CAB.................................................................................................................... 368 FUNCTION OF ROPS CAB..................................................................................................................... 369 CAB MOUNT.................................................................................................................................... 370 STRUCTURE OF CAB MOUNT................................................................................................................... 370 FUNCTION OF CAB MOUNT.................................................................................................................... 370 20 STANDARD VALUE TABLE.............................................................................................................................. 371 CONTENTS......................................................................................................................................... 372 ABBREVIATION LIST................................................................................................................................ 373 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................. 379 STANDARD VALUE TABLE FOR ENGINE: D61EX-24.................................................................................................... 379 STANDARD VALUE TABLE FOR ENGINE: D61PX-24.................................................................................................... 383 STANDARD VALUE TABLE FOR MACHINE................................................................................................................. 387 STANDARD VALUE TABLE FOR MACHINE: D61EX-24................................................................................................... 387 STANDARD VALUE TABLE FOR MACHINE: D61PX-24................................................................................................... 403 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...................................................................................... 419 30 TESTING AND ADJUSTING............................................................................................................................. 421 CONTENTS......................................................................................................................................... 422 ABBREVIATION LIST................................................................................................................................ 425 RELATED INFORMATION ON TESTING AND ADJUSTING..................................................................................................... 431 TOOLS FOR TESTING AND ADJUSTING.............................................................................................................. 431 SKETCH OF TOOLS FOR TESTING AND ADJUSTING.................................................................................................... 438 ENGINE AND COOLING SYSTEM........................................................................................................................ 439 TEST ENGINE SPEED............................................................................................................................ 439 METHOD FOR TESTING ENGINE SPEED.......................................................................................................... 439 TEST BOOST PRESSURE.......................................................................................................................... 442 METHOD FOR TESTING BOOST PRESSURE........................................................................................................ 442 TEST EXHAUST GAS COLOR....................................................................................................................... 444 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER.............................................................................. 444 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...................................................................................... 446 TEST AND ADJUST VALVE CLEARANCE.............................................................................................................. 448 METHOD FOR TESTING VALVE CLEARANCE....................................................................................................... 448 METHOD FOR ADJUSTING VALVE CLEARANCE..................................................................................................... 449 TEST COMPRESSION PRESSURE.................................................................................................................... 450 METHOD FOR TESTING COMPRESSION PRESSURE.................................................................................................. 450 TEST BLOWBY PRESSURE......................................................................................................................... 455 METHOD FOR TESTING BLOWBY PRESSURE....................................................................................................... 455 TEST ENGINE OIL PRESSURE..................................................................................................................... 457 METHOD FOR TESTING ENGINE OIL PRESSURE................................................................................................... 457 TEST EGR VALVE AND VGT OIL PRESSURE.......................................................................................................... 458 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE........................................................................................ 458 TEST FUEL PRESSURE........................................................................................................................... 460 METHOD FOR TESTING FUEL PRESSURE......................................................................................................... 461 TEST FUEL DISCHARGE, RETURN AND LEAKAGE...................................................................................................... 466 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE.................................................................................... 467 BLEEDING AIR FROM FUEL SYSTEM................................................................................................................ 473 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM................................................................................................. 473 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................................ 474 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE.............................................................................................. 474 HANDLE CYLINDER CUT-OUT MODE OPERATION....................................................................................................... 476 HANDLE NO-INJECTION CRANKING OPERATION....................................................................................................... 477 TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE.................................................................................... 478 METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE.................................................................. 478 TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS..................................................................................... 479 METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS................................................................... 479 TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS.................................................................................................. 480 METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS................................................................................ 480 TEST ALTERNATOR BELT......................................................................................................................... 481 METHOD FOR REMOVING ALTERNATOR BELT...................................................................................................... 481 TEST AUTOMATIC TENSIONER..................................................................................................................... 483 METHOD FOR TESTING AUTOMATIC TENSIONER................................................................................................... 483 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER............................................................................... 485 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.............................................................. 485 TEST SCR RELATED FUNCTIONS................................................................................................................... 486 TEST AdBlue/DEF PUMP RAISED PRESSURE..................................................................................................... 490 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR........................................................................................... 493 TEST AdBlue/DEF LINE HEATER RELAY 1...................................................................................................... 498 TEST AdBlue/DEF LINE HEATER RELAY 2...................................................................................................... 501 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................................ 504 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................................ 508 TEST DENITRATION EFFICIENCY OF SCR....................................................................................................... 512 CLEAN AdBlue/DEF TANK........................................................................................................................ 515 METHOD FOR CLEANING AdBlue/DEF TANK...................................................................................................... 515 CLEAN AdBlue/DEF TANK MOUNTING PORTION....................................................................................................... 519 METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION..................................................................................... 519 POWER TRAIN...................................................................................................................................... 520 TEST AND ADJUST HST OIL PRESSURE............................................................................................................. 520 METHOD FOR TESTING HST OIL PRESSURE...................................................................................................... 520 METHOD FOR ADJUSTING HST OIL PRESSURE.................................................................................................... 523 BLEED AIR FROM HST PUMP...................................................................................................................... 525 METHOD FOR BLEEDING AIR FROM HST PUMP.................................................................................................... 525 METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP..................................................................................... 525 TEST OUTLET PRESSURE OF SOLENOID VALVE....................................................................................................... 527 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE..................................................................................... 527 TEST TRAVEL DEVIATION........................................................................................................................ 532 METHOD FOR TESTING TRAVEL DEVIATION...................................................................................................... 532 TEST BRAKE PERFORMANCE SIMPLY................................................................................................................ 534 METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY.............................................................................................. 534 TEST AND ADJUST DECELERATION/BRAKE PEDAL..................................................................................................... 535 METHOD FOR TESTING DECELERATION/BRAKE PEDAL.............................................................................................. 535 METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL............................................................................................ 537 ADJUST PARKING BRAKE LEVER................................................................................................................... 539 METHOD FOR ADJUSTING PARKING BRAKE LEVER................................................................................................. 539 MOVE MACHINE WHEN IT CANNOT TRAVEL........................................................................................................... 541 METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM............................................................... 541 METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT......................................................................... 543 UNDERCARRIAGE AND FRAME.......................................................................................................................... 545 CHECK AND ADJUST IDLER CLEARANCE............................................................................................................. 545 METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE........................................................................................ 545 TESTING SPROCKET WEAR........................................................................................................................ 546 METHOD FOR TESTING SPROCKET WEAR......................................................................................................... 546 TEST AND ADJUST TRACK TENSION................................................................................................................ 547 METHOD FOR TESTING TRACK TENSION......................................................................................................... 547 METHOD FOR ADJUSTING TRACK TENSION....................................................................................................... 547 HYDRAULIC SYSTEM................................................................................................................................. 549 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................................................................. 549 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT........................................................................... 549 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES................................................................................................. 550 METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES.......................................................................................... 550 METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES........................................................................................ 551 TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT.............................................................................................. 553 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT....................................................................................... 553 METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT..................................................................................... 554 TEST OUTLET PRESSURE OF EPC SOLENOID VALVE................................................................................................... 555 METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE................................................................................. 555 BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP........................................................................................... 557 METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP......................................................................... 557 TEST COOLING FAN SPEED....................................................................................................................... 558 METHOD FOR TESTING COOLING FAN SPEED..................................................................................................... 558 TEST COOLING FAN CIRCUIT OIL PRESSURE........................................................................................................ 559 METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE...................................................................................... 559 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT..................................................................................... 561 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER.............................................................. 561 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER.............................................................. 562 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER............................................................. 563 TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER......................................................................................... 564 METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER....................................................................... 564 BLEED AIR FROM WORK EQUIPMENT CYLINDERS...................................................................................................... 566 METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS.................................................................................... 566 WORK EQUIPMENT................................................................................................................................... 567 ADJUST WORK EQUIPMENT LOCK LEVER............................................................................................................. 567 METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER........................................................................................... 567 ELECTRICAL SYSTEM................................................................................................................................ 569 SET AND OPERATE MACHINE MONITOR.............................................................................................................. 569 OPERATOR MODE............................................................................................................................ 573 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN.............................................................................. 573 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN................................................................................. 573 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................................ 574 CHECKING FUNCTION OF SERVICE METER....................................................................................................... 574 METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD.................................................................... 574 SERVICE MODE............................................................................................................................. 577 METHOD FOR OPERATING SERVICE MODE........................................................................................................ 577 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION................................................................................... 579 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION................................................................................... 585 ABNORMALITY RECORD MENU.................................................................................................................. 595 METHOD FOR CONFIRMING MAINTENANCE RECORD................................................................................................. 599 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................................ 600 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING.......................................................................................... 604 DEFAULT MENU............................................................................................................................. 606 DIAGNOSTIC TESTS MENU.................................................................................................................... 613 ADJUSTMENT MENU.......................................................................................................................... 622 METHOD FOR PERFORMING NO-INJECTION CRANKING.............................................................................................. 677 KOMTRAX SETTINGS MENU.................................................................................................................... 680 METHOD FOR DISPLAYING SERVICE MESSAGE.................................................................................................... 682 METHOD FOR STARTING UP KOMTRAX TERMINAL...................................................................................................... 684 ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED............................................................................................. 689 ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED.................................................................................. 689 ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED............................................................................... 695 ADJUST REARVIEW CAMERA ANGLE................................................................................................................. 697 METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE............................................................................................... 697 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER.................................................................................................. 698 HANDLE BATTERY DISCONNECT SWITCH............................................................................................................. 699 TEST DIODES.................................................................................................................................. 700 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................................ 700 METHOD FOR TESTING DIODE USING ANALOG TESTER............................................................................................. 700 Pm CLINIC........................................................................................................................................ 701 Pm CLINIC SERVICE............................................................................................................................ 701 PM CLINIC CHECK SHEET: D61EX-24.......................................................................................................... 703 PM CLINIC CHECK SHEET: D61PX-24.......................................................................................................... 710 PM CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EX-24........................................................................................ 717 PM CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PX-24........................................................................................ 720 40 TROUBLESHOOTING................................................................................................................................... 723 CONTENTS......................................................................................................................................... 724 ABBREVIATION LIST................................................................................................................................ 734 RELATED INFORMATION ON TROUBLESHOOTING........................................................................................................... 740 GENERAL TROUBLESHOOTING POINTS............................................................................................................... 740 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM................................................................................................... 741 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................ 753 CHECKS BEFORE TROUBLESHOOTING................................................................................................................ 755 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING.................................................................................................. 757 WALK-AROUND CHECK........................................................................................................................ 757 TESTING IN ACCORDANCE WITH TESTING PROCEDURE................................................................................................. 759 CHECK FUEL LEVEL AND TYPE................................................................................................................ 759 CHECK IMPURE INGREDIENT IN FUEL.......................................................................................................... 759 CHECK AdBule/DEF LEVEL AND TYPE.......................................................................................................... 760 CHECK FUEL PREFILTER..................................................................................................................... 760 CHECK MAIN FILTER........................................................................................................................ 762 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE.................................................................................. 763 CHECK COOLANT LEVEL (RESERVOIR TANK)..................................................................................................... 764 CHECK CLOGGING OF AIR CLEANER............................................................................................................ 765 CLEAN OUTER ELEMENT...................................................................................................................... 765 REPLACE ELEMENT.......................................................................................................................... 767 CHECK HYDRAULIC OIL LEVEL................................................................................................................ 768 CHECK HYDRAULIC OIL STRAINER............................................................................................................. 769 CHECK HYDRAULIC FILTER................................................................................................................... 772 CHECK OIL LEVEL IN FINAL DRIVE CASE...................................................................................................... 773 BLEED AIR FROM FUEL SYSTEM............................................................................................................... 774 BLEED AIR FROM HYDRAULIC SYSTEM.......................................................................................................... 774 METHOD FOR CHECKING ELECTRIC EQUIPMENT................................................................................................... 774 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM......................................................................................... 781 PROCEDURE FOR TROUBLESHOOTING................................................................................................................ 788 SYMPTOM AND TROUBLESHOOTING NUMBERS.......................................................................................................... 791 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE............................................................................................... 794 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM.......................................................... 796 CONNECTORS LIST AND LAYOUT................................................................................................................... 799 CONNECTOR CONTACT IDENTIFICATION............................................................................................................. 813 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...................................................................................................... 853 FUSE LOCATION TABLE.......................................................................................................................... 859 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC).................................................................................. 863 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]).................................................. 867 FAILURE CODES TABLE.......................................................................................................................... 869 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................................ 887 FAILURE CODE [6091NX]........................................................................................................................ 887 FAILURE CODE [989L00]........................................................................................................................ 889 FAILURE CODE [989M00]........................................................................................................................ 890 FAILURE CODE [989N00]........................................................................................................................ 891 FAILURE CODE [A1U0N3]........................................................................................................................ 892 FAILURE CODE [A1U0N4]........................................................................................................................ 894 FAILURE CODE [A900FR]........................................................................................................................ 896 FAILURE CODE [A900N6]........................................................................................................................ 897 FAILURE CODE [A900NY]........................................................................................................................ 898 FAILURE CODE [AA10NX]........................................................................................................................ 899 FAILURE CODE [AB00KE]........................................................................................................................ 901 FAILURE CODE [AQ10N3]........................................................................................................................ 903 FAILURE CODE [AS00N3]........................................................................................................................ 905 FAILURE CODE [AS00R2]........................................................................................................................ 907 FAILURE CODE [AS00R3]........................................................................................................................ 908 FAILURE CODE [AS00R4]........................................................................................................................ 909 FAILURE CODE [AS00R5]........................................................................................................................ 910 FAILURE CODE [AS00R6]........................................................................................................................ 911 FAILURE CODE [AS00ZK]........................................................................................................................ 912 FAILURE CODE [AS10KM]........................................................................................................................ 913 FAILURE CODE [AS10NR]........................................................................................................................ 914 FAILURE CODE [AS10NT]........................................................................................................................ 915 FAILURE CODE [B@BAZG]........................................................................................................................ 916 FAILURE CODE [B@BCNS]........................................................................................................................ 917 FAILURE CODE [B@CRNS]........................................................................................................................ 918 FAILURE CODE [B@CRZG]........................................................................................................................ 919 FAILURE CODE [CA115]......................................................................................................................... 920 FAILURE CODE [CA122]......................................................................................................................... 921 FAILURE CODE [CA123]......................................................................................................................... 923 FAILURE CODE [CA131]......................................................................................................................... 925 FAILURE CODE [CA132]......................................................................................................................... 927 FAILURE CODE [CA144]......................................................................................................................... 929 FAILURE CODE [CA145]......................................................................................................................... 931 FAILURE CODE [CA153]......................................................................................................................... 933 FAILURE CODE [CA154]......................................................................................................................... 936 FAILURE CODE [CA187]......................................................................................................................... 938 FAILURE CODE [CA221]......................................................................................................................... 940 FAILURE CODE [CA222]......................................................................................................................... 942 FAILURE CODE [CA227]......................................................................................................................... 944 FAILURE CODE [CA234]......................................................................................................................... 945 FAILURE CODE [CA238]......................................................................................................................... 946 FAILURE CODE [CA239]......................................................................................................................... 948 FAILURE CODE [CA249]......................................................................................................................... 950 FAILURE CODE [CA256]......................................................................................................................... 952 FAILURE CODE [CA271]......................................................................................................................... 954 FAILURE CODE [CA272]......................................................................................................................... 956 FAILURE CODE [CA322]......................................................................................................................... 958 FAILURE CODE [CA323]......................................................................................................................... 960 FAILURE CODE [CA324]......................................................................................................................... 962 FAILURE CODE [CA325]......................................................................................................................... 964 FAILURE CODE [CA331]......................................................................................................................... 966 FAILURE CODE [CA332]......................................................................................................................... 968 FAILURE CODE [CA343]......................................................................................................................... 970 FAILURE CODE [CA351]......................................................................................................................... 971 FAILURE CODE [CA352]......................................................................................................................... 972 FAILURE CODE [CA356]......................................................................................................................... 975 FAILURE CODE [CA357]......................................................................................................................... 977 FAILURE CODE [CA386]......................................................................................................................... 980 FAILURE CODE [CA428]......................................................................................................................... 981 FAILURE CODE [CA429]......................................................................................................................... 983 FAILURE CODE [CA435]......................................................................................................................... 985 FAILURE CODE [CA441]......................................................................................................................... 987 FAILURE CODE [CA442]......................................................................................................................... 989 FAILURE CODE [CA449]......................................................................................................................... 990 FAILURE CODE [CA451]......................................................................................................................... 991 FAILURE CODE [CA452]......................................................................................................................... 993 FAILURE CODE [CA488]......................................................................................................................... 995 FAILURE CODE [CA515]......................................................................................................................... 996 FAILURE CODE [CA516]......................................................................................................................... 998 FAILURE CODE [CA553].........................................................................................................................1000 FAILURE CODE [CA555].........................................................................................................................1001 FAILURE CODE [CA556].........................................................................................................................1002 FAILURE CODE [CA559].........................................................................................................................1003 FAILURE CODE [CA595].........................................................................................................................1006 FAILURE CODE [CA687].........................................................................................................................1007 FAILURE CODE [CA689].........................................................................................................................1009 FAILURE CODE [CA691].........................................................................................................................1012 FAILURE CODE [CA692].........................................................................................................................1014 FAILURE CODE [CA697].........................................................................................................................1016 FAILURE CODE [CA698].........................................................................................................................1017 FAILURE CODE [CA731].........................................................................................................................1018 FAILURE CODE [CA778].........................................................................................................................1020 FAILURE CODE [CA1117]........................................................................................................................1025 FAILURE CODE [CA1664]........................................................................................................................1026 FAILURE CODE [CA1669]........................................................................................................................1029 FAILURE CODE [CA1673]........................................................................................................................1030 FAILURE CODE [CA1677]........................................................................................................................1031 FAILURE CODE [CA1678]........................................................................................................................1032 FAILURE CODE [CA1682]........................................................................................................................1033 FAILURE CODE [CA1683]........................................................................................................................1037 FAILURE CODE [CA1684]........................................................................................................................1039 FAILURE CODE [CA1686]........................................................................................................................1041 FAILURE CODE [CA1691]........................................................................................................................1042 FAILURE CODE [CA1694]........................................................................................................................1045 FAILURE CODE [CA1695]........................................................................................................................1048 FAILURE CODE [CA1696]........................................................................................................................1049 FAILURE CODE [CA1712]........................................................................................................................1051 FAILURE CODE [CA1713]........................................................................................................................1054 FAILURE CODE [CA1714]........................................................................................................................1056 FAILURE CODE [CA1715]........................................................................................................................1057 FAILURE CODE [CA1776]........................................................................................................................1058 FAILURE CODE [CA1777]........................................................................................................................1061 FAILURE CODE [CA1843]........................................................................................................................1064 FAILURE CODE [CA1844]........................................................................................................................1066 FAILURE CODE [CA1879]........................................................................................................................1069 FAILURE CODE [CA1881]........................................................................................................................1072 FAILURE CODE [CA1883]........................................................................................................................1074 FAILURE CODE [CA1885]........................................................................................................................1078 FAILURE CODE [CA1887]........................................................................................................................1080 FAILURE CODE [CA1921]........................................................................................................................1082 FAILURE CODE [CA1922]........................................................................................................................1085 FAILURE CODE [CA1942]........................................................................................................................1090 FAILURE CODE [CA1993]........................................................................................................................1091 FAILURE CODE [CA2185]........................................................................................................................1094 FAILURE CODE [CA2186]........................................................................................................................1096 FAILURE CODE [CA2249]........................................................................................................................1098 FAILURE CODE [CA2271]........................................................................................................................1099 FAILURE CODE [CA2272]........................................................................................................................1102 FAILURE CODE [CA2288]........................................................................................................................1105 FAILURE CODE [CA2311]........................................................................................................................1106 FAILURE CODE [CA2349]........................................................................................................................1107 FAILURE CODE [CA2353]........................................................................................................................1110 FAILURE CODE [CA2357]........................................................................................................................1112 FAILURE CODE [CA2381]........................................................................................................................1113 FAILURE CODE [CA2382]........................................................................................................................1116 FAILURE CODE [CA2383]........................................................................................................................1119 FAILURE CODE [CA2386]........................................................................................................................1122 FAILURE CODE [CA2387]........................................................................................................................1124 FAILURE CODE [CA2555]........................................................................................................................1125 FAILURE CODE [CA2556]........................................................................................................................1128 FAILURE CODE [CA2637]........................................................................................................................1131 FAILURE CODE [CA2639]........................................................................................................................1133 FAILURE CODE [CA2771]........................................................................................................................1136 FAILURE CODE [CA2777]........................................................................................................................1142 FAILURE CODE [CA2976]........................................................................................................................1145 FAILURE CODE [CA3133]........................................................................................................................1147 FAILURE CODE [CA3134]........................................................................................................................1149 FAILURE CODE [CA3135]........................................................................................................................1151 FAILURE CODE [CA3142]........................................................................................................................1155 FAILURE CODE [CA3143]........................................................................................................................1156 FAILURE CODE [CA3144]........................................................................................................................1157 FAILURE CODE [CA3146]........................................................................................................................1159 FAILURE CODE [CA3147]........................................................................................................................1160 FAILURE CODE [CA3148]........................................................................................................................1161 FAILURE CODE [CA3151]........................................................................................................................1163 FAILURE CODE [CA3165]........................................................................................................................1169 FAILURE CODE [CA3229]........................................................................................................................1171 FAILURE CODE [CA3231]........................................................................................................................1173 FAILURE CODE [CA3232]........................................................................................................................1175 FAILURE CODE [CA3235]........................................................................................................................1179 FAILURE CODE [CA3239]........................................................................................................................1181 FAILURE CODE [CA3241]........................................................................................................................1184 FAILURE CODE [CA3242]........................................................................................................................1187 FAILURE CODE [CA3251]........................................................................................................................1190 FAILURE CODE [CA3253]........................................................................................................................1192 FAILURE CODE [CA3254]........................................................................................................................1195 FAILURE CODE [CA3255]........................................................................................................................1198 FAILURE CODE [CA3256]........................................................................................................................1201 FAILURE CODE [CA3311]........................................................................................................................1203 FAILURE CODE [CA3312]........................................................................................................................1205 FAILURE CODE [CA3313]........................................................................................................................1208 FAILURE CODE [CA3314]........................................................................................................................1209 FAILURE CODE [CA3315]........................................................................................................................1210 FAILURE CODE [CA3316]........................................................................................................................1213 FAILURE CODE [CA3317]........................................................................................................................1214 FAILURE CODE [CA3318]........................................................................................................................1215 FAILURE CODE [CA3319]........................................................................................................................1218 FAILURE CODE [CA3321]........................................................................................................................1219 FAILURE CODE [CA3322]........................................................................................................................1221 FAILURE CODE [CA3419]........................................................................................................................1224 FAILURE CODE [CA3421]........................................................................................................................1226 FAILURE CODE [CA3497]........................................................................................................................1228 FAILURE CODE [CA3498]........................................................................................................................1229 FAILURE CODE [CA3543]........................................................................................................................1230 FAILURE CODE [CA3545]........................................................................................................................1237 FAILURE CODE [CA3547]........................................................................................................................1239 FAILURE CODE [CA3558]........................................................................................................................1240 FAILURE CODE [CA3559]........................................................................................................................1242 FAILURE CODE [CA3562]........................................................................................................................1244 FAILURE CODE [CA3563]........................................................................................................................1246 FAILURE CODE [CA3567]........................................................................................................................1249 FAILURE CODE [CA3568]........................................................................................................................1252 FAILURE CODE [CA3571]........................................................................................................................1258 FAILURE CODE [CA3572]........................................................................................................................1260 FAILURE CODE [CA3574]........................................................................................................................1262 FAILURE CODE [CA3575]........................................................................................................................1264 FAILURE CODE [CA3577]........................................................................................................................1266 FAILURE CODE [CA3578]........................................................................................................................1268 FAILURE CODE [CA3582]........................................................................................................................1270 FAILURE CODE [CA3583]........................................................................................................................1278 FAILURE CODE [CA3596]........................................................................................................................1280 FAILURE CODE [CA3649]........................................................................................................................1283 FAILURE CODE [CA3681]........................................................................................................................1285 FAILURE CODE [CA3682]........................................................................................................................1290 FAILURE CODE [CA3713]........................................................................................................................1296 FAILURE CODE [CA3717]........................................................................................................................1299 FAILURE CODE [CA3718]........................................................................................................................1300 FAILURE CODE [CA3725]........................................................................................................................1301 FAILURE CODE [CA3741]........................................................................................................................1304 FAILURE CODE [CA3748]........................................................................................................................1305 FAILURE CODE [CA3751]........................................................................................................................1307 FAILURE CODE [CA3755]........................................................................................................................1309 FAILURE CODE [CA3866]........................................................................................................................1311 FAILURE CODE [CA3867]........................................................................................................................1315 FAILURE CODE [CA3868]........................................................................................................................1318 FAILURE CODE [CA3899]........................................................................................................................1322 FAILURE CODE [CA3911]........................................................................................................................1324 FAILURE CODE [CA3912]........................................................................................................................1328 FAILURE CODE [CA3932]........................................................................................................................1330 FAILURE CODE [CA3933]........................................................................................................................1332 FAILURE CODE [CA3934]........................................................................................................................1334 FAILURE CODE [CA3935]........................................................................................................................1337 FAILURE CODE [CA3936]........................................................................................................................1339 FAILURE CODE [CA4151]........................................................................................................................1341 FAILURE CODE [CA4152]........................................................................................................................1345 FAILURE CODE [CA4155]........................................................................................................................1349 FAILURE CODE [CA4156]........................................................................................................................1351 FAILURE CODE [CA4157]........................................................................................................................1354 FAILURE CODE [CA4158]........................................................................................................................1356 FAILURE CODE [CA4159]........................................................................................................................1357 FAILURE CODE [CA4161]........................................................................................................................1358 FAILURE CODE [CA4162]........................................................................................................................1361 FAILURE CODE [CA4163]........................................................................................................................1364 FAILURE CODE [CA4164]........................................................................................................................1366 FAILURE CODE [CA4165]........................................................................................................................1368 FAILURE CODE [CA4166]........................................................................................................................1370 FAILURE CODE [CA4168]........................................................................................................................1372 FAILURE CODE [CA4169]........................................................................................................................1375 FAILURE CODE [CA4171]........................................................................................................................1377 FAILURE CODE [CA4249]........................................................................................................................1380 FAILURE CODE [CA4251]........................................................................................................................1382 FAILURE CODE [CA4259]........................................................................................................................1384 FAILURE CODE [CA4261]........................................................................................................................1387 FAILURE CODE [CA4277]........................................................................................................................1390 FAILURE CODE [CA4281]........................................................................................................................1394 FAILURE CODE [CA4459]........................................................................................................................1397 FAILURE CODE [CA4461]........................................................................................................................1400 FAILURE CODE [CA4658]........................................................................................................................1403 FAILURE CODE [CA4731]........................................................................................................................1407 FAILURE CODE [CA4732]........................................................................................................................1408 FAILURE CODE [CA4739]........................................................................................................................1409 FAILURE CODE [CA4768]........................................................................................................................1410 FAILURE CODE [CA4769]........................................................................................................................1412 FAILURE CODE [CA4842]........................................................................................................................1415 FAILURE CODE [CA4952]........................................................................................................................1419 FAILURE CODE [CA5115]........................................................................................................................1421 FAILURE CODE [CA5383]........................................................................................................................1424 FAILURE CODE [D130KA]........................................................................................................................1426 FAILURE CODE [D130KB]........................................................................................................................1429 FAILURE CODE [D130KY]........................................................................................................................1431 FAILURE CODE [D19JKZ]........................................................................................................................1433 FAILURE CODE [D811MC]........................................................................................................................1436 FAILURE CODE [D862KA]........................................................................................................................1437 FAILURE CODE [D8ALKA]........................................................................................................................1438 FAILURE CODE [D8ALKB]........................................................................................................................1440 FAILURE CODE [D8AQKR]........................................................................................................................1442 FAILURE CODE [DAF0MB]........................................................................................................................1444 FAILURE CODE [DAF0MC]........................................................................................................................1445 FAILURE CODE [DAF8KB]........................................................................................................................1446 FAILURE CODE [DAF9KQ]........................................................................................................................1448 FAILURE CODE [DAFGMC]........................................................................................................................1449 FAILURE CODE [DAFLKA]........................................................................................................................1450 FAILURE CODE [DAFLKB]........................................................................................................................1452 FAILURE CODE [DAFQKR]........................................................................................................................1454 FAILURE CODE [DAJ000]........................................................................................................................1455 FAILURE CODE [DAJ0KQ]........................................................................................................................1456 FAILURE CODE [DAJ0KT]........................................................................................................................1457 FAILURE CODE [DAJ0MC]........................................................................................................................1458 FAILURE CODE [DAJ1KK]........................................................................................................................1459 FAILURE CODE [DAJ2KK]........................................................................................................................1461 FAILURE CODE [DAJ5KK]........................................................................................................................1463 FAILURE CODE [DAJ6KK]........................................................................................................................1466 FAILURE CODE [DAJLKA]........................................................................................................................1468 FAILURE CODE [DAJLKB]........................................................................................................................1470 FAILURE CODE [DAJPMA]........................................................................................................................1472 FAILURE CODE [DAJQKR]........................................................................................................................1473 FAILURE CODE [DAJRKR]........................................................................................................................1474 FAILURE CODE [DB2QKR]........................................................................................................................1475 FAILURE CODE [DB2RKR]........................................................................................................................1480 FAILURE CODE [DD12KA]........................................................................................................................1485 FAILURE CODE [DD12KB]........................................................................................................................1487 FAILURE CODE [DD13KA]........................................................................................................................1489 FAILURE CODE [DD13KB]........................................................................................................................1491 FAILURE CODE [DD14KA]........................................................................................................................1493 FAILURE CODE [DD14KB]........................................................................................................................1495 FAILURE CODE [DDKAKA]........................................................................................................................1497 FAILURE CODE [DDKAKB]........................................................................................................................1499 FAILURE CODE [DDKFL4]........................................................................................................................1501 FAILURE CODE [DDKGL4]........................................................................................................................1503 FAILURE CODE [DDKHKA]........................................................................................................................1505 FAILURE CODE [DDKHKB]........................................................................................................................1507 FAILURE CODE [DDNLKA]........................................................................................................................1509 FAILURE CODE [DDNLKB]........................................................................................................................1511 FAILURE CODE [DDP6KA]........................................................................................................................1513 FAILURE CODE [DDP6KB]........................................................................................................................1516 FAILURE CODE [DDP6MA]........................................................................................................................1518 FAILURE CODE [DDU1FS]........................................................................................................................1520 FAILURE CODE [DDU1KA]........................................................................................................................1522 FAILURE CODE [DDU1KY]........................................................................................................................1525 FAILURE CODE [DFA4KX]........................................................................................................................1527 FAILURE CODE [DFA4KZ]........................................................................................................................1528 FAILURE CODE [DFA4L8]........................................................................................................................1529 FAILURE CODE [DFA5KA]........................................................................................................................1530 FAILURE CODE [DFA5KB]........................................................................................................................1533 FAILURE CODE [DFA6KA]........................................................................................................................1536 FAILURE CODE [DFA6KB]........................................................................................................................1539 FAILURE CODE [DFA7KX]........................................................................................................................1542 FAILURE CODE [DFA7KZ]........................................................................................................................1543 FAILURE CODE [DFA7L8]........................................................................................................................1544 FAILURE CODE [DFA8KA]........................................................................................................................1545 FAILURE CODE [DFA8KB]........................................................................................................................1548 FAILURE CODE [DFA9KA]........................................................................................................................1551 FAILURE CODE [DFA9KB]........................................................................................................................1554 FAILURE CODE [DGS1KA]........................................................................................................................1557 FAILURE CODE [DGS1KX]........................................................................................................................1560 FAILURE CODE [DH21KA]........................................................................................................................1561 FAILURE CODE [DH21KB]........................................................................................................................1563 FAILURE CODE [DHA4KA]........................................................................................................................1565 FAILURE CODE [DHAAMA]........................................................................................................................1567 FAILURE CODE [DHACMA]........................................................................................................................1569 FAILURE CODE [DHH7KA]........................................................................................................................1571 FAILURE CODE [DHH7KB]........................................................................................................................1574 FAILURE CODE [DHH8KA]........................................................................................................................1576 FAILURE CODE [DHH8KB]........................................................................................................................1579 FAILURE CODE [DHH9KA]........................................................................................................................1581 FAILURE CODE [DHH9KB]........................................................................................................................1584 FAILURE CODE [DHHAKA]........................................................................................................................1586 FAILURE CODE [DHHAKB]........................................................................................................................1589 FAILURE CODE [DK30KA]........................................................................................................................1591 FAILURE CODE [DK30KB]........................................................................................................................1594 FAILURE CODE [DK30KX]........................................................................................................................1596 FAILURE CODE [DK30KZ]........................................................................................................................1597 FAILURE CODE [DK30L8]........................................................................................................................1598 FAILURE CODE [DK31KA]........................................................................................................................1599 FAILURE CODE [DK31KB]........................................................................................................................1602 FAILURE CODE [DK40KA]........................................................................................................................1604 FAILURE CODE [DK40KB]........................................................................................................................1607 FAILURE CODE [DK55KX]........................................................................................................................1609 FAILURE CODE [DK55KZ]........................................................................................................................1610 FAILURE CODE [DK55L8]........................................................................................................................1611 FAILURE CODE [DK56KA]........................................................................................................................1612 FAILURE CODE [DK56KB]........................................................................................................................1615 FAILURE CODE [DK57KA]........................................................................................................................1617 FAILURE CODE [DK57KB]........................................................................................................................1620 FAILURE CODE [DLM0KX]........................................................................................................................1622 FAILURE CODE [DLM1KA]........................................................................................................................1623 FAILURE CODE [DLM1KB]........................................................................................................................1625 FAILURE CODE [DLM1MA]........................................................................................................................1627 FAILURE CODE [DLM2KA]........................................................................................................................1628 FAILURE CODE [DLM2KB]........................................................................................................................1630 FAILURE CODE [DLM2MA]........................................................................................................................1632 FAILURE CODE [DLM3KA]........................................................................................................................1633 FAILURE CODE [DLM3KB]........................................................................................................................1635 FAILURE CODE [DLM3MB]........................................................................................................................1637 FAILURE CODE [DN21FS]........................................................................................................................1638 FAILURE CODE [DR21KX]........................................................................................................................1640 FAILURE CODE [DR31KX]........................................................................................................................1641 FAILURE CODE [DV20KB]........................................................................................................................1642 FAILURE CODE [DW4BKA]........................................................................................................................1644 FAILURE CODE [DW4BKB]........................................................................................................................1646 FAILURE CODE [DW4BKY]........................................................................................................................1648 FAILURE CODE [DW7BKA]........................................................................................................................1650 FAILURE CODE [DW7BKB]........................................................................................................................1652 FAILURE CODE [DW7EKA]........................................................................................................................1654 FAILURE CODE [DW7EKB]........................................................................................................................1656 FAILURE CODE [DW7EKY]........................................................................................................................1658 FAILURE CODE [DWN5KA]........................................................................................................................1660 FAILURE CODE [DWN5KB]........................................................................................................................1662 FAILURE CODE [DWN5KY]........................................................................................................................1664 FAILURE CODE [DXA4KA]........................................................................................................................1666 FAILURE CODE [DXA4KB]........................................................................................................................1668 FAILURE CODE [DXA4KY]........................................................................................................................1670 FAILURE CODE [DXA5KA]........................................................................................................................1672 FAILURE CODE [DXA5KB]........................................................................................................................1674 FAILURE CODE [DXA5KY]........................................................................................................................1676 FAILURE CODE [DXA6KA]........................................................................................................................1678 FAILURE CODE [DXA6KB]........................................................................................................................1680 FAILURE CODE [DXA6KY]........................................................................................................................1682 FAILURE CODE [DXA7KA]........................................................................................................................1684 FAILURE CODE [DXA7KB]........................................................................................................................1686 FAILURE CODE [DXA7KY]........................................................................................................................1688 FAILURE CODE [DXHRKA]........................................................................................................................1690 FAILURE CODE [DXHRKB]........................................................................................................................1692 FAILURE CODE [DXHRKY]........................................................................................................................1694 FAILURE CODE [DXHSKA]........................................................................................................................1696 FAILURE CODE [DXHSKB]........................................................................................................................1698 FAILURE CODE [DXHSKY]........................................................................................................................1700 FAILURE CODE [DXHTKA]........................................................................................................................1702 FAILURE CODE [DXHTKB]........................................................................................................................1704 FAILURE CODE [DXHTKY]........................................................................................................................1706 FAILURE CODE [DXHUKA]........................................................................................................................1708 FAILURE CODE [DXHUKB]........................................................................................................................1710 FAILURE CODE [DXHUKY]........................................................................................................................1712 FAILURE CODE [DXJ4KA]........................................................................................................................1714 FAILURE CODE [DXJ4KB]........................................................................................................................1716 FAILURE CODE [DXJCKA]........................................................................................................................1718 FAILURE CODE [DXJCKB]........................................................................................................................1720 FAILURE CODE [DXJCKY]........................................................................................................................1722 FAILURE CODE [DXJDKA]........................................................................................................................1724 FAILURE CODE [DXJDKB]........................................................................................................................1726 FAILURE CODE [DXJDKY]........................................................................................................................1728 FAILURE CODE [DXK1KA]........................................................................................................................1730 FAILURE CODE [DXK1KB]........................................................................................................................1732 FAILURE CODE [DXK1KY]........................................................................................................................1734 FAILURE CODE [DXK2KA]........................................................................................................................1736 FAILURE CODE [DXK2KB]........................................................................................................................1738 FAILURE CODE [DXK2KY]........................................................................................................................1740 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....................................................................................................1742 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)............................................................................................1742 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...................................................................................................1749 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK................................................................................................1752 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP........................................................................1754 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING..........................................................1756 E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP.......................................1760 E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.................................................................1761 E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING............................................................................1762 E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1763 E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................................................................1764 E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................................................................1765 E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1766 E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................1767 E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE..................................................................1768 E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL........................................................................................1769 E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE...................................................................1772 E-17 OPERATION MODE DOES NOT CHANGE..........................................................................................................1773 E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN............................................................................1774 E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE................................................................1775 E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION................................................................1776 E-21 SERVICE MODE CANNOT BE SELECTED.........................................................................................................1777 E-22 WORK EQUIPMENT DOES NOT OPERATE.........................................................................................................1778 E-23 FOOT HEATER DOES NOT OPERATE............................................................................................................1780 E-24 HORN DOES NOT SOUND.....................................................................................................................1786 E-25 HORN DOES NOT STOP SOUNDING.............................................................................................................1788 E-26 BACKUP ALARM DOES NOT SOUND.............................................................................................................1789 E-27 BACKUP ALARM DOES NOT STOP SOUNDING.....................................................................................................1790 E-28 HEADLAMP DOES NOT LIGHT UP..............................................................................................................1791 E-29 REAR LAMP DOES NOT LIGHT UP.............................................................................................................1795 E-30 ALL WIPERS DO NOT OPERATE...............................................................................................................1798 E-31 FRONT WIPER DOES NOT OPERATE............................................................................................................1800 E-32 REAR WIPER DOES NOT OPERATE.............................................................................................................1802 E-33 LEFT DOOR WIPER DOES NOT OPERATE........................................................................................................1804 E-34 RIGHT DOOR WIPER DOES NOT OPERATE.......................................................................................................1808 E-35 FRONT WASHER DOES NOT OPERATE...........................................................................................................1812 E-36 REAR WASHER DOES NOT OPERATE............................................................................................................1814 E-37 LEFT DOOR WASHER DOES NOT OPERATE.......................................................................................................1816 E-38 RIGHT DOOR WASHER DOES NOT OPERATE......................................................................................................1818 E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY................................................................................................1820 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....................................................................................1821 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)......................................................................................1821 FAILURE MODE AND CAUSE TABLE.................................................................................................................1822 H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE).......................................1828 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)..................1830 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)....1832 H-4 TRAVEL SPEED OR POWER IS LOW.............................................................................................................1834 H-5 SPEED RANGE DOES NOT CHANGE..............................................................................................................1836 H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS...........................................................................................1837 H-7 MACHINE DEVIATES LARGELY.................................................................................................................1838 H-8 MACHINE DRIFT ON A SLOPE IS LARGE........................................................................................................1841 H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...............................................................................................1843 H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR....................................................................................1845 H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH..........................................................................1847 H-12 ALL WORK EQUIPMENT DO NOT OPERATE.......................................................................................................1849 H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW...............................................................................................1851 H-14 BLADE LIFT SPEED OR POWER IS LOW........................................................................................................1852 H-15 BLADE TILT SPEED OR POWER IS LOW........................................................................................................1854 H-16 BLADE ANGLE SPEED OR POWER IS LOW.......................................................................................................1855 H-17 TIME LAG OF BLADE LIFT IS LARGE.........................................................................................................1856 H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE................................................................................................1857 H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE................................................................................................1858 H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE.................................................1859 H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)..................................................................................1860 H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN..................................................................................................1862 TROUBLESHOOTING OF ENGINE (S-MODE)...............................................................................................................1863 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)......................................................................................1863 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...................................................................1864 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...............................................................................................1865 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...........................................1866 S-4 ENGINE STARTABILITY IS POOR..............................................................................................................1868 S-5 ENGINE DOES NOT PICK UP SMOOTHLY.........................................................................................................1870 S-6 ENGINE STOPS DURING OPERATION............................................................................................................1872 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE.........................................................................................................1874 S-8 ENGINE LACKS POWER.......................................................................................................................1875 S-9 KDPF GETS CLOGGED IN A SHORT TIME........................................................................................................1877 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE.....................................................................................................1879 S-11 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................1880 S-12 FUEL CONSUMPTION IS EXCESSIVE...........................................................................................................1881 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...................................................................1882 S-14 OIL PRESSURE DROPS......................................................................................................................1883 S-15 FUEL MIXES INTO ENGINE OIL..............................................................................................................1885 S-16 WATER MIXES INTO ENGINE OIL (MILKY).....................................................................................................1886 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)........................................................................................1887 S-18 UNUSUAL NOISE IS HEARD..................................................................................................................1888 S-19 VIBRATION IS EXCESSIVE..................................................................................................................1889 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT....................................................................................................1890 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY..............................................................................................1891 S-22 ACTIVE REGENERATION TAKES TIME..........................................................................................................1893 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.....................................................................................1894 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE.....................................................................................................1895 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)................................................................................................1897 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...............................................................................1898 50 DISASSEMBLY AND ASSEMBLY..........................................................................................................................1899 CONTENTS.........................................................................................................................................1900 ABBREVIATION LIST................................................................................................................................1905 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY..................................................................................................1911 HOW TO READ THIS MANUAL......................................................................................................................1911 COATING MATERIALS LIST.......................................................................................................................1913 SPECIAL TOOLS LIST...........................................................................................................................1917 SKETCHES OF SPECIAL TOOLS....................................................................................................................1936 ENGINE AND COOLING SYSTEM........................................................................................................................1949 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY......................................................................................................1949 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY.................................................................................................1949 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...............................................................................................1955 REMOVE AND INSTALL INJECTOR ASSEMBLY.........................................................................................................1962 METHOD FOR REMOVING INJECTOR ASSEMBLY....................................................................................................1962 METHOD FOR INSTALLING INJECTOR ASSEMBLY..................................................................................................1969 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY....................................................................................................1979 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...............................................................................................1979 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY.............................................................................................1991 REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................................................2009 METHOD FOR REMOVING EGR VALVE ASSEMBLY...................................................................................................2009 METHOD FOR INSTALLING EGR VALVE ASSEMBLY.................................................................................................2010 REMOVE AND INSTALL EGR COOLER ASSEMBLY.......................................................................................................2012 METHOD FOR REMOVING EGR COOLER ASSEMBLY..................................................................................................2012 METHOD FOR INSTALLING EGR COOLER ASSEMBLY................................................................................................2014 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...................................................................................................2017 METHOD FOR REMOVING STARTING MOTOR ASSEMBLY..............................................................................................2017 METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY............................................................................................2019 REMOVE AND INSTALL ALTERNATOR BELT...........................................................................................................2021 METHOD FOR REMOVING ALTERNATOR BELT......................................................................................................2021 METHOD FOR INSTALLING ALTERNATOR BELT....................................................................................................2022 REMOVE AND INSTALL AUTOMATIC TENSIONER.......................................................................................................2024 METHOD FOR REMOVING AUTOMATIC TENSIONER..................................................................................................2024 METHOD FOR INSTALLING AUTOMATIC TENSIONER................................................................................................2024 REMOVE AND INSTALL RADIATOR ASSEMBLY.........................................................................................................2025 METHOD FOR REMOVING RADIATOR ASSEMBLY....................................................................................................2025 METHOD FOR INSTALLING RADIATOR ASSEMBLY..................................................................................................2028 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY.............................................................................................2032 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY........................................................................................2032 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY......................................................................................2035 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY......................................................................................................2038 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY.................................................................................................2038 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...............................................................................................2041 REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY................................................................................................2045 METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY...........................................................................................2045 METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY.........................................................................................2048 REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY................................................................................................2052 METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY...........................................................................................2052 METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY.........................................................................................2055 REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY.................................................................................................2059 METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY............................................................................................2059 METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY..........................................................................................2068 REMOVE AND INSTALL ENGINE FRONT OIL SEAL.....................................................................................................2079 METHOD FOR REMOVING ENGINE FRONT OIL SEAL................................................................................................2079 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL..............................................................................................2080 REMOVE AND INSTALL ENGINE REAR OIL SEAL......................................................................................................2082 METHOD FOR REMOVING ENGINE REAR OIL SEAL.................................................................................................2082 METHOD FOR INSTALLING ENGINE REAR OIL SEAL...............................................................................................2084 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY......................................................................................................2087 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY.................................................................................................2087 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...............................................................................................2090 REMOVE AND INSTALL FUEL TANK ASSEMBLY........................................................................................................2093 METHOD FOR REMOVING FUEL TANK ASSEMBLY...................................................................................................2093 METHOD FOR INSTALLING FUEL TANK ASSEMBLY.................................................................................................2099 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY..................................................................................................2105 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY.............................................................................................2105 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...........................................................................................2111 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY....................................................................................2117 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...............................................................................2117 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.............................................................................2118 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR....................................................................................................2121 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...............................................................................................2121 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR.............................................................................................2122 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER..................................................................................................2129 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER.............................................................................................2129 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...........................................................................................2130 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER........................................................................................2131 METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER...................................................................................2131 METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER.................................................................................2132 REMOVE AND INSTALL KDPF ASSEMBLY.............................................................................................................2135 METHOD FOR REMOVING KDPF ASSEMBLY........................................................................................................2136 METHOD FOR INSTALLING KDPF ASSEMBLY......................................................................................................2139 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY....................................................................................................2142 METHOD FOR DISASSEMBLING KDPF ASSEMBLY...................................................................................................2142 METHOD FOR ASSEMBLING KDPF ASSEMBLY......................................................................................................2145 REMOVE AND INSTALL SCR ASSEMBLY..............................................................................................................2152 METHOD FOR REMOVING SCR ASSEMBLY.........................................................................................................2152 METHOD FOR INSTALLING SCR ASSEMBLY.......................................................................................................2154 REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................................................2158 METHOD FOR REMOVING KDPF, SCR ASSEMBLY...................................................................................................2159 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY.................................................................................................2165 REMOVE AND INSTALL KCCV ASSEMBLY.............................................................................................................2172 METHOD FOR REMOVING KCCV ASSEMBLY........................................................................................................2172 METHOD FOR INSTALLING KCCV ASSEMBLY......................................................................................................2174 REMOVE AND INSTALL VGT ASSEMBLY..............................................................................................................2176 METHOD FOR REMOVING VGT ASSEMBLY.........................................................................................................2176 METHOD FOR INSTALLING VGT ASSEMBLY.......................................................................................................2178 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE....................................................................................................2181 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...............................................................................................2182 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE.............................................................................................2184 REMOVE AND INSTALL AdBlue/DEF INJECTOR.......................................................................................................2188 METHOD FOR REMOVING AdBlue/DEF INJECTOR..................................................................................................2188 METHOD FOR INSTALLING AdBlue/DEF INJECTOR................................................................................................2191 REMOVE AND INSTALL AdBlue/DEF PUMP...........................................................................................................2195 METHOD FOR REMOVING AdBlue/DEF PUMP......................................................................................................2195 METHOD FOR INSTALLING AdBlue/DEF PUMP....................................................................................................2198 REMOVE AND INSTALL AdBlue/DEF HOSE...........................................................................................................2201 METHOD FOR REMOVING AdBlue/DEF HOSE......................................................................................................2201 METHOD FOR INSTALLING AdBlue/DEF HOSE....................................................................................................2205 REMOVE AND INSTALL AIR CLEANER ASSEMBLY......................................................................................................2211 METHOD FOR REMOVING AIR CLEANER ASSEMBLY.................................................................................................2211 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...............................................................................................2213 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.......................................................................................2216 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................................2216 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY................................................................................2217 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY........................................................................................2219 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...................................................................................2219 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY.................................................................................2223 POWER TRAIN......................................................................................................................................2227 REMOVE AND INSTALL DAMPER ASSEMBLY...........................................................................................................2227 METHOD FOR REMOVING DAMPER ASSEMBLY......................................................................................................2227 METHOD FOR INSTALLING DAMPER ASSEMBLY....................................................................................................2228 REMOVE AND INSTALL HST PUMP ASSEMBLY.........................................................................................................2230 METHOD FOR REMOVING HST PUMP ASSEMBLY....................................................................................................2230 METHOD FOR INSTALLING HST PUMP ASSEMBLY..................................................................................................2232 REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY........................................................................................2234 METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY...................................................................................2234 METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY.................................................................................2237 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY................................................................................................2240 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY............................................................................................2241 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...............................................................................................2259 REMOVE AND INSTALL IDLER ASSEMBLY............................................................................................................2264 METHOD FOR REMOVING IDLER ASSEMBLY.......................................................................................................2264 METHOD FOR INSTALLING IDLER ASSEMBLY.....................................................................................................2266 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY......................................................................................................2268 METHOD FOR DISASSEMBLING IDLER ASSEMBLY..................................................................................................2268 METHOD FOR ASSEMBLING IDLER ASSEMBLY.....................................................................................................2270 REMOVE AND INSTALL RECOIL SPRING ASSEMBLY....................................................................................................2275 METHOD FOR REMOVING RECOIL SPRING ASSEMBLY...............................................................................................2275 METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY.............................................................................................2276 DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY..............................................................................................2277 METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY...........................................................................2277 METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY.............................................................................................2280 REMOVE AND INSTALL TRACK ROLLER ASSEMBLY.....................................................................................................2283 METHOD FOR REMOVING TRACK ROLLER ASSEMBLY................................................................................................2283 METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY..............................................................................................2284 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY...............................................................................................2287 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY...........................................................................................2287 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................................2289 REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY...................................................................................................2293 METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY..............................................................................................2293 METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY............................................................................................2294 DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY.............................................................................................2296 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY.........................................................................................2296 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................................2297 REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY......................................................................................................2300 METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY.................................................................................................2300 METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY...............................................................................................2301 SEPARATE AND CONNECT TRACK ASSEMBLY..........................................................................................................2303 METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY.....................................................................................2303 METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)............................................................................................2304 METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT)..............................................................2305 METHOD FOR CONNECTING TRACK ASSEMBLY.....................................................................................................2306 SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY................................................................................................2308 METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY...........................................................................................2308 METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY...........................................................................................2308 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........................................................................2345 METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD....................................................................2346 METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD.......................................................................2347 DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD..............................................................2354 METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD..........................................................2355 METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD.............................................................2357 REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY....................................................................................................2361 METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY...............................................................................................2361 METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY.............................................................................................2363 REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS...............................................................................................2366 METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS..........................................................................................2366 METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS........................................................................................2366 REMOVE AND INSTALL SEGMENT TEETH.............................................................................................................2368 METHOD FOR REMOVING SEGMENT TEETH........................................................................................................2368 METHOD FOR INSTALLING SEGMENT TEETH......................................................................................................2369 HYDRAULIC SYSTEM.................................................................................................................................2370 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...................................................................................................2370 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY..............................................................................................2371 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY............................................................................................2375 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY....................................................................................................2380 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...............................................................................................2380 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY.............................................................................................2385 WORK EQUIPMENT...................................................................................................................................2390 REMOVE AND INSTALL BLADE ASSEMBLY............................................................................................................2390 METHOD FOR REMOVING BLADE ASSEMBLY.......................................................................................................2390 METHOD FOR INSTALLING BLADE ASSEMBLY.....................................................................................................2392 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...................................................................................................2395 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY..............................................................................................2395 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY............................................................................................2397 METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.....................................................................2399 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY................................................................................2400 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................................2401 REMOVE AND INSTALL U-FRAME ASSEMBLY..........................................................................................................2405 METHOD FOR REMOVING U-FRAME ASSEMBLY.....................................................................................................2405 METHOD FOR INSTALLING U-FRAME ASSEMBLY...................................................................................................2407 CAB AND ITS ATTACHMENTS..........................................................................................................................2409 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...................................................................................................2409 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY..............................................................................................2409 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY............................................................................................2416 REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)......................................................................................2423 METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS).................................................................................2425 METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...............................................................................2425 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY.............................................................................................2431 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY........................................................................................2431 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY......................................................................................2437 REMOVE AND INSTALL RECEIVER DRIER............................................................................................................2444 METHOD FOR REMOVING RECEIVER DRIER.......................................................................................................2444 METHOD FOR INSTALLING RECEIVER DRIER.....................................................................................................2445 REMOVE AND INSTALL OPERATOR'S SEAT...........................................................................................................2448 METHOD FOR REMOVING OPERATOR'S SEAT......................................................................................................2448 METHOD FOR INSTALLING OPERATOR'S SEAT....................................................................................................2449 REMOVE AND INSTALL SEAT BELT.................................................................................................................2450 METHOD FOR REMOVING SEAT BELT............................................................................................................2450 METHOD FOR INSTALLING SEAT BELT..........................................................................................................2450 REMOVE AND INSTALL FOOT HEATER ASSEMBLY......................................................................................................2452 METHOD FOR REMOVING FOOT HEATER ASSEMBLY.................................................................................................2452 METHOD FOR INSTALLING FOOT HEATER ASSEMBLY...............................................................................................2454 DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY................................................................................................2457 METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY............................................................................................2457 METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY...............................................................................................2458 ELECTRICAL SYSTEM................................................................................................................................2459 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY................................................................................................2459 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...........................................................................................2459 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY.........................................................................................2460 REMOVE AND INSTALL HST CONTROLLER ASSEMBLY...................................................................................................2464 METHOD FOR REMOVING HST CONTROLLER ASSEMBLY..............................................................................................2464 METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY............................................................................................2465 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY..................................................................................................2466 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY.............................................................................................2466 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...........................................................................................2467 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR......................................................................................2469 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR.................................................................................2469 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...............................................................................2471 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR............................................................................................2472 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR.......................................................................................2472 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR.....................................................................................2474 REMOVE AND INSTALL SCR TEMPERATURE SENSOR....................................................................................................2476 METHOD FOR REMOVING SCR TEMPERATURE SENSOR...............................................................................................2476 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR.............................................................................................2477 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY.................................................................................................2479 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY............................................................................................2479 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY..........................................................................................2480 60 MAINTENANCE STANDARD..............................................................................................................................2481 CONTENTS.........................................................................................................................................2482 ABBREVIATION LIST................................................................................................................................2484 ENGINE AND COOLING SYSTEM........................................................................................................................2490 MAINTENANCE STANDARD OF ENGINE MOUNT.........................................................................................................2490 MAINTENANCE STANDARD OF DAMPER...............................................................................................................2491 MAINTENANCE STANDARD OF COOLING SYSTEM.......................................................................................................2492 MAINTENANCE STANDARD OF COOLING FAN MOTOR....................................................................................................2494 MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP..................................................................................2496 POWER TRAIN......................................................................................................................................2497 MAINTENANCE STANDARD OF HST PUMP.............................................................................................................2497 MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP............................................................................................2498 MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP..................................................................................2499 MAINTENANCE STANDARD OF HST CHARGE PUMP......................................................................................................2500 MAINTENANCE STANDARD OF HST MOTOR............................................................................................................2502 MAINTENANCE STANDARD OF FINAL DRIVE..........................................................................................................2503 MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE............................................................................2505 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE...........................................2506 MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE....................................................................................2508 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE...................................................2509 UNDERCARRIAGE AND FRAME..........................................................................................................................2511 MAINTENANCE STANDARD OF SUSPENSION...........................................................................................................2511 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION........................................................................................2513 MAINTENANCE STANDARD OF IDLER................................................................................................................2515 MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE)..................................................2517 MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE)..................................................2518 MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)..........................................................2519 MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)..........................................................2520 MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE......................................................................2521 MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE..............................................................................2522 MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE.........................................................................................2523 MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE.................................................................................................2525 MAINTENANCE STANDARD OF SINGLE SHOE..........................................................................................................2527 MAINTENANCE STANDARD OF SWAMP SHOE...........................................................................................................2528 HYDRAULIC SYSTEM.................................................................................................................................2529 MAINTENANCE STANDARD OF HYDRAULIC TANK.......................................................................................................2529 MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP..................................................................................2530 MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP...............................................................2531 MAINTENANCE STANDARD OF CONTROL VALVE........................................................................................................2533 MAINTENANCE STANDARD OF RIPPER PPC VALVE.....................................................................................................2540 MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID.....................................................................................2542 MAINTENANCE STANDARD OF EPC VALVE........................................................................................................2543 MAINTENANCE STANDARD OF ANGLE OPERATION 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................................................................................................................................2558 MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER......................................................................................2558 80 APPENDIX..........................................................................................................................................2559 CONTENTS.........................................................................................................................................2560 ABBREVIATION LIST................................................................................................................................2561 AIR CONDITIONER SYSTEM...........................................................................................................................2567 PRECAUTIONS FOR REFRIGERANT..................................................................................................................2567 AIR CONDITIONER COMPONENT....................................................................................................................2568 SPECIFICATIONS OF AIR CONDITIONER............................................................................................................2571 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE............................................................................................2572 OUTLINE OF REFRIGERATION CYCLE...............................................................................................................2573 COMPONENT PARTS OF AIR CONDITIONER SYSTEM........................................................................................................2575 AIR CONDITIONER UNIT.........................................................................................................................2575 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT............................................................................................2575 FUNCTION OF AIR CONDITIONER UNIT.........................................................................................................2576 COMPONENT PARTS OF AIR CONDITIONER UNIT......................................................................................................2577 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT.................................................................................2577 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT................................................................................2577 FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT.................................................................................2577 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...........................................................................2578 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT............................................................................2578 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT................................................................................2578 FUNCTION OF DUAL PRESSURE SWITCH.........................................................................................................2579 FUNCTION OF PRESSURE SWITCH..............................................................................................................2579 COMPRESSOR...................................................................................................................................2580 STRUCTURE OF COMPRESSOR..................................................................................................................2580 SPECIFICATIONS OF COMPRESSOR.............................................................................................................2580 FUNCTION OF COMPRESSOR...................................................................................................................2580 CONDENSER....................................................................................................................................2581 STRUCTURE OF CONDENSER...................................................................................................................2581 SPECIFICATIONS OF CONDENSER..............................................................................................................2581 FUNCTION OF CONDENSER....................................................................................................................2582 RECEIVER DRIER...............................................................................................................................2583 STRUCTURE OF RECEIVER DRIER..............................................................................................................2583 SPECIFICATIONS OF RECEIVER DRIER.........................................................................................................2583 FUNCTION OF RECEIVER DRIER...............................................................................................................2583 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......................................................................2585 CIRCUIT DIAGRAM OF AIR CONDITIONER...............................................................................................................2588 AIR CONDITIONER SYSTEM DIAGRAM...................................................................................................................2589 CONTROL FUNCTION OF AIR CONDITIONER..............................................................................................................2590 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS....................................................................2591 TEST RELAYS......................................................................................................................................2595 METHOD FOR TESTING RELAYS....................................................................................................................2595 AIR CONDITIONER TROUBLESHOOTING CHART 1..........................................................................................................2597 AIR CONDITIONER TROUBLESHOOTING CHART 2..........................................................................................................2598 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...................................................................................................2601 A-1 TROUBLESHOOTING FOR CONDENSER FAN............................................................................................................2603 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)....................................................................2606 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...........................................................2610 A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION.............................................................................................2613 TROUBLESHOOTING USING GAUGE PRESSURE.............................................................................................................2617 CONNECTION OF SERVICE TOOL.......................................................................................................................2619 METHOD FOR CONNECTING SERVICE TOOL...........................................................................................................2619 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS..........................................................2620 HANDLE COMPRESSOR OIL............................................................................................................................2622 90 CIRCUIT DIAGRAMS..................................................................................................................................2625 CONTENTS.........................................................................................................................................2626 ABBREVIATION LIST................................................................................................................................2627 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................2633 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM....................................................................................................2633 HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................2637 ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................................2639 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...................................................................................................2639 ELECTRICAL CIRCUIT DIAGRAM (1/14)............................................................................................................2643 ELECTRICAL CIRCUIT DIAGRAM (2/14)............................................................................................................2645 ELECTRICAL CIRCUIT DIAGRAM (3/14)............................................................................................................2647 ELECTRICAL CIRCUIT DIAGRAM (4/14)............................................................................................................2649 ELECTRICAL CIRCUIT DIAGRAM (5/14)............................................................................................................2651 ELECTRICAL CIRCUIT DIAGRAM (6/14)............................................................................................................2653 ELECTRICAL CIRCUIT DIAGRAM (7/14)............................................................................................................2655 ELECTRICAL CIRCUIT DIAGRAM (8/14)............................................................................................................2657 ELECTRICAL CIRCUIT DIAGRAM (9/14)............................................................................................................2659 ELECTRICAL CIRCUIT DIAGRAM (10/14)...........................................................................................................2661 ELECTRICAL CIRCUIT DIAGRAM (11/14)...........................................................................................................2663 ELECTRICAL CIRCUIT DIAGRAM (12/14)...........................................................................................................2665 ELECTRICAL CIRCUIT DIAGRAM (13/14)...........................................................................................................2667 ELECTRICAL CIRCUIT DIAGRAM (14/14)...........................................................................................................2669 INDEX.................................................................................................................................................2671
DESCRIPTION:
KOMATSU D61EX-24 D61PX-24 BULLDOZER SHOP MANUAL SEN06577-06 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
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