Komatsu D61EX-24 D61PX-24 Bulldozer Shop Manual SEN06577-12 PDF
$39.95
Komatsu D61EX-24 D61PX-24 Bulldozer Shop Manual SEN06577-12 – PDF DOWNLOAD
D61PX-40001 and up
Description
Komatsu D61EX-24 D61PX-24 Bulldozer Shop Manual SEN06577-12 – PDF DOWNLOAD
FILE DETAILS:
Komatsu D61EX-24 D61PX-24 Bulldozer Shop Manual SEN06577-12 – PDF DOWNLOAD
Language : English
Pages : 2864
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu D61EX-24 D61PX-24 Bulldozer Shop Manual SEN06577-12 – PDF DOWNLOAD
D61PX-40001 and up
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
TABLE OF CONTENTS:
Komatsu D61EX-24 D61PX-24 Bulldozer Shop Manual SEN06577-12 – PDF DOWNLOAD
D61PX-40001 and up
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
Procedures If Fire Occurs 39
Precautions When You Discard Waste Materials 40
Procedures for Exhaust Gas Regulations 41
Precautions for DEF 42
General Character and Precautions for Handling 42
Precautions When You Add 42
Precautions for Storage 42
Precautions for Fire Hazard and Leakage 42
Other Precautions 42
Store DEF 43
Precautions When You Handle Hydraulic Equipment 44
Precautions When You Disconnect and Connect Pipings 47
Precautions When You Handle Electrical Equipment 54
Precautions When You Handle Fuel System Equipment 56
Precautions When You Handle Intake System Equipment 57
Practical Use of KOMTRAX 58
Disconnect and Connect Push-Pull Type Coupler 59
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 60
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 61
Precautions for Disconnection and Connection of Connectors 63
Disconnect and Connect Deutsch Connector 67
How to Disconnect and Connect Slide Lock Type Connector 68
Disconnect and Connect Connector with Lock to Pull 70
Disconnect and Connect Connector with Lock to Push 71
Disconnect and Connect Connector with Housing to Rotate 73
How to Read the Codes for Electric Cable 74
Explanation of Terms for Maintenance Standard 78
Standard Tightening Torque Table 81
Conversion Table 88
01 Specification 93
Table of 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
Table of 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 DEF System 133
Inducement Strategy 135
Component Parts of Urea SCR System 149
DEF Mixing Tube 149
SCR Assembly 150
DEF Tank 152
DEF Pump 154
DEF Injector 155
DEF Hose 156
DEF Tank Heating Valve 157
Boot-up System 158
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 158
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 159
System Operating Lamp System 160
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 160
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 160
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 160
Function of System Operating Lamp System (Machine with Gateway Function Controller) 161
Battery Disconnect Switch 163
Layout Drawing of Battery Disconnect Switch 163
Function of Battery Disconnect Switch 163
Engine System 165
Layout Drawing of Engine System 165
Engine Control System 167
Layout of Engine Control System (Machine with KOMTRAX Terminal) 167
Layout of Engine Control System (Machine with Gateway Function Controller) 169
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 171
System Diagram of Engine Control System (Machine with Gateway Function Controller) 173
Function of Engine Control System (Machine with KOMTRAX Terminal) 175
Function of Engine Control System (Machine with Gateway Function Controller) 177
Automatic Idle Stop System 179
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 179
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 180
Function of Automatic Idle Stop System 180
Component Parts of Engine System 183
Damper 183
VGT 184
EGR System 188
EGR Valve 190
EGR Cooler 192
KCCV System 194
KCCV Ventilator 196
KDPF 198
Cooling System 202
Layout Drawing of Cooling System 202
Specifications of Cooling System 203
Cooling Fan Control System 204
System Diagram of Cooling Fan Control System 204
Function of Cooling Fan Control System 205
Component Parts of Cooling System 207
Cooling Fan Motor 207
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 212
Hydraulic Oil Cooler Bypass Valve 214
HST Charge Safety Valve 215
Control System 217
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 217
Layout Drawing of Control System (Machine with Gateway Function Controller) 218
Machine Monitor System 219
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 219
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 220
Function of Machine Monitor System 220
KOMTRAX System 221
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 221
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 221
Function of KOMTRAX System 222
Component Parts of Control System 223
Machine Monitor 223
KOMTRAX Terminal 238
Gateway Function Controller 240
Communication Terminal 243
HST Controller 245
Engine Controller 249
Decelerator and Brake Potentiometer 256
Hydraulic System 258
Layout Drawing of Hydraulic System 258
CLSS 259
Structure of CLSS 259
Function of CLSS 260
Component Parts of Hydraulic System 262
Hydraulic Tank 262
Work Equipment and Cooling Fan Pump 264
LS Valve 272
PC Valve 273
Control Valve 276
Power Train System 297
Layout Drawing of HST System 297
Operation of HST System 298
Steering and Brake Control System 300
Layout Drawing of Steering and Brake Control System 300
Function of Steering and Brake Control System 300
HST Control System 302
System Diagram of HST Control System 302
Gear Shift Control Function 303
Engine Low Speed Matching Control Function 307
HST Pump and Motor Sequence Control Function 307
Deceleration and Brake Control Function 309
Gear Shift Control Function by Load 310
Turn Control Function 310
Straight Travel Correction Control Function 311
Parking Brake Control System 313
System Diagram of Parking Brake Control System 313
Function of Parking Brake Control System 314
Operation of Parking Brake Control System 315
Component Parts of Power Train System 316
HST Pump 316
HST Charge Pump 333
HST Motor 334
Final Drive 346
Electric Steering Electric Lever 350
Work Equipment System 353
Work Equipment Control 353
Layout Drawing of Work Equipment Control 353
Function of Work Equipment Control 354
Layout Drawing of Front Work Equipment 356
Layout Drawing of Fixed Multi-Shank Ripper 357
Component Parts of Work Equipment System 358
Ripper PPC Valve 358
5-Spool EPC and Solenoid Valve 362
Pilot Circuit Accumulator 368
Angle Control EPC Valve 369
Quick Drop Valve 372
Piston Valve 374
Electric Blade Control Lever 375
Undercarriage and Frame 377
Main Frame 377
Structure of Main Frame 377
Suspension 378
Structure of Suspension 378
Specifications of Suspension 379
Function of Suspension 380
Track Frame and Idler Cushion 381
Structure of Track Frame and Idler Cushion 381
Function of Track Frame and Idler Cushion 383
Work Equipment 384
Structure of Front Work Equipment 384
Structure of Fixed Multi-Shank Ripper 385
CAB Related Parts 386
ROPS CAB 386
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 386
Structure of ROPS CAB (Machine with Gateway Function Controller) 387
Function of ROPS CAB 388
CAB Mount 389
Structure of CAB Mount 389
Function of CAB Mount 389
20 Standard Value Table 391
Table of Contents 392
Abbreviation List 393
Standard Value Table for Engine 399
Standard Value Table for Engine: D61EX-24 399
Standard Value Table for Engine: D61PX-24 403
Standard Value Table for Machine 407
Standard Value Table for Machine: D61EX-24 407
Standard Value Table for Machine: D61PX-24 423
Machine Posture and Procedures to Measure Performance 439
30 Testing and Adjusting 441
Table of Contents 442
Precautions Before Work 445
Abbreviation List 446
Related Information on Testing and Adjusting 452
Tools for Testing and Adjusting 452
Sketch of Tools for Testing and Adjusting 460
Engine and Cooling System 463
Examine Engine Speed 463
How to Examine Engine Speed 463
Examine Boost Pressure 466
How to Examine Boost Pressure 466
Examine Exhaust Gas Color 468
How to Examine Exhaust Gas Color with the Handy Smoke Checker 468
How to Examine Exhaust Gas Color with Smoke Meter 470
Examine Mass Air Flow and Temperature Sensor 472
How to Examine Mass Air Flow and Temperature Sensor 472
Examine and Adjust Valve Clearance 474
Check Valve Clearance 474
Adjust Valve Clearance 475
Examine Compression Pressure 476
How to Examine Compression Pressure 476
Examine Blowby Pressure 481
How to Examine Blowby Pressure 481
Examine Engine Oil Pressure 484
How to Examine Engine Oil Pressure 484
Examine EGR Valve and VGT Oil Pressure 485
How to Examine EGR Valve and VGT Oil Pressure 485
Examine Fuel Pressure 487
How to Examine Fuel Pressure 488
Examine Fuel Discharge, Return and Leakage 493
How to Examine Fuel Discharge, Return, and Leakage 494
Bleed Air from Fuel System 500
How to Bleed Air from Fuel System 500
Examine Fuel Circuit for Leakage 501
How to Examine Fuel System for Leakage 501
Handle Cylinder Cut-out Mode Operation 503
Handle No-Injection Cranking Operation 504
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 505
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 505
Examine Installed Condition of Cylinder Heads and Manifolds 506
How to Examine Installed Condition of Cylinder Heads and Manifolds 506
Examine Engine Piping for Damage and Looseness 507
How to Examine Engine Piping for Damage and Looseness 507
Examine Alternator Belt 508
How to Examine Alternator Belt 508
Examine Automatic Tensioner 510
How to Examine Automatic Tensioner 510
Write Correction for Ash in Soot Accumulation to Engine Controller 512
How to Write Correction for Ash in Soot Accumulation to Engine Controller 512
Examine SCR Related Functions 513
Examine DEF Pump Raised Pressure 517
Examine Injection Volume from DEF Injector 520
Examine DEF Line Heater Relay 1 525
Examine DEF Line Heater Relay 2 528
Examine DEF Pump Heater Relay 531
Examine DEF Tank Heater Valve 535
Examine SCR Denitration Efficiency 539
Clean DEF Tank 542
How to Clean DEF Tank 542
Clean DEF Tank Mounting Part 546
How to Clean DEF Tank Mounting Part 546
Clean DEF Pump 547
How to Clean DEF Pump 547
Power Train 553
Examine and Adjust HST Oil Pressure 553
Examine HST Oil Pressure 553
Adjust HST Oil Pressure 556
Bleed Air from HST Pump 558
How to Bleed Air from HST Pump 558
Bleed Air from Servo Valve of HST Pump 558
Examine Outlet Pressure of Solenoid Valve 560
How to Examine Outlet Pressure of Solenoid Valve 560
Examine Travel Deviation 565
How to Examine Travel Deviation 565
Examine Brake Performance Simply 567
How to Examine Brake Performance Simply 567
Examine and Adjust Deceleration/Brake Pedal 568
How to Examine Deceleration/Brake Pedal 568
How to Adjust Deceleration/Brake Pedal 570
Adjust Parking Brake Lever 572
How to Adjust Parking Brake Lever 572
Move Machine When It Cannot Travel 574
Move Machine with Hydraulic Type Parking Brake Release System 574
Move Machine After You Remove Final Drive Shaft 576
Undercarriage and Frame 578
Examine and Adjust Idler Clearance 578
How to Examine and Adjust Idler Clearance 578
Examine Sprocket Wear 579
How to Examine Sprocket Wear 579
Examine and Adjust Track Tension 580
How to Examine Track Tension 580
How to Adjust Track Tension 580
Hydraulic System 582
Release Remained Pressure in Hydraulic Circuit 582
How to Release Remained Pressure in Hydraulic System 582
Examine and Adjust Work Equipment Circuit Oil Pressure 583
How to Examine Work Equipment Circuit Oil Pressure 583
Adjust Work Equipment Circuit Oil Pressure 584
Examine and Adjust Oil Pressure in Control Circuit 586
Examine Oil Pressure in Control Circuit 586
Adjust Oil Pressure in Control Circuit 587
Examine Outlet Pressure of EPC Solenoid Valve 588
How to Examine Outlet Pressure of EPC Solenoid Valve 588
Bleed Air from Work Equipment and Cooling Fan Pump 590
How to Bleed Air from Work Equipment and Cooling Fan Pump 590
Examine Cooling Fan Speed 591
How to Examine Cooling Fan Speed 591
Examine Cooling Fan Circuit Oil Pressure 592
How to Examine Cooling Fan Circuit Oil Pressure 592
Examine Parts Which Cause Hydraulic Drift of Work Equipment 594
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 594
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 594
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 595
Examine Oil Leakage from Work Equipment Cylinder 596
How to Examine Internal Oil Leakage of Work Equipment Cylinder 596
Bleed Air from Work Equipment Cylinders 598
Bleed Air from Work Equipment Cylinder 598
Work Equipment 599
Adjust Work Equipment Lock Lever 599
How to Adjust Work Equipment Lock Lever 599
Examine and Adjust Play of Blade Electric Lever 601
How to Examine Play of Blade Electric Lever 603
Adjust Play of Blade Electric Lever 603
Replace Universal Joint 604
Electrical System 611
Set and Operate Machine Monitor 611
Operator Mode 615
Function to Show Technician Identification Status Screen 615
Function to Show Operator Identification Input Screen 615
Examine Function by LCD (Liquid Crystal Display) 616
Examine Function of Service Meter 616
Usage Limitation and Change Maintenance Password 616
Service Mode 619
How to Operate Service Mode 619
How to See Pre-defined Monitoring Information 621
How to Examine Self-Define Monitor Information 627
Abnormality Record Menu 637
How to See Maintenance Record 641
Maintenance Mode Setting 642
Set Phone Number Entry 646
Default Menu 648
Diagnostic Tests Menu 655
Adjustment Menu 664
No-Injection Cranking Operation 719
KOMTRAX Settings Menu 722
Show Service Message 726
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 728
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 733
Start Up KOMTRAX System (Machine with Gateway Function Controller) 735
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 741
Adjust After Replacement of HST Controller 743
How to Adjust After Replacement of HST Controller 743
Adjust After Replacement of Electric and Hydraulic Equipment 749
Adjust Rearview Camera Angle 751
How to Adjust Rearview Camera Angle 751
Handle Voltage Circuit of Engine Controller 752
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 753
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 754
Examine Diodes 755
Examine Diodes by Digital Tester 755
How to Examine Diodes by Analog Tester 755
Pm Clinic 756
Pm Clinic Service 756
Pm Clinic Check Sheet: D61EX-24 758
Pm Clinic Check Sheet: D61PX-24 765
Pm Clinic Check Sheet for Undercarriage: D61EX-24 772
Pm Clinic Check Sheet for Undercarriage: D61PX-24 775
40 Troubleshooting 779
Table of Contents 780
Precautions Before Work 790
Abbreviation List 791
Related Information to Troubleshooting 797
General Troubleshooting Points 797
Troubleshooting Points for Urea SCR System 798
Sequence of Events in Troubleshooting 812
Checks Before Troubleshooting 814
Inspection Procedure Before Troubleshooting 816
Walk-Around Check 816
Test in Accordance with Testing Procedure 818
Examine Fuel Level and Type 818
Examine for Impure Ingredient in Fuel 818
Examine DEF Level and Type 819
Examine Fuel Prefilter 819
Examine Fuel Main Filter 821
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 822
Examine Coolant Level (Reservoir Tank) 823
Examine Air Cleaner Clogging 824
Clean Outer Element 824
Replace Element 827
Examine Hydraulic Oil Level 827
Examine Hydraulic Oil Strainer 828
Examine Hydraulic Oil Filter 832
Examine Oil Level in Final Drive Case 833
Bleed Air from Fuel System 833
Bleed Air from Hydraulic System 833
How to Examine Electric Equipment 833
Preparation for Troubleshooting of Electrical System 840
Procedure for Troubleshooting 847
Symptom and Troubleshooting Numbers 850
Information Shown in Troubleshooting Table 853
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 855
Connector List and Layout (Machine with KOMTRAX Terminal) 858
Connector List and Layout (Machine with Gateway Function Controller) 872
Connector Contact Connection Table 886
T-Branch Box and T-Branch Adapter Table 926
Fuse Location Table (Machine with KOMTRAX Terminal) 932
Fuse Location Table (Machine with Gateway Function Controller) 936
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 940
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 944
Failure Codes Table (Machine with KOMTRAX Terminal) 946
Failure Codes Table (Machine with Gateway Function Controller) 964
Troubleshooting by Failure Code (Display of Code) 983
Failure Code [6091NX] 983
Failure Code [989L00] 985
Failure Code [989M00] 986
Failure Code [989N00] 987
Failure Code [A1U0N3] 988
Failure Code [A1U0N4] 990
Failure Code [A900FR] 992
Failure Code [A900N6] 993
Failure Code [A900NY] 994
Failure Code [AA10NX] 995
Failure Code [AB00KE] 997
Failure Code [AQ10N3] 999
Failure Code [AS00N3] 1001
Failure Code [AS00R2] 1003
Failure Code [AS00R3] 1004
Failure Code [AS00R4] 1005
Failure Code [AS00R5] 1006
Failure Code [AS00R6] 1007
Failure Code [AS00ZK] 1008
Failure Code [AS10KM] 1009
Failure Code [AS10NR] 1010
Failure Code [AS10NT] 1011
Failure Code [B@BAZG] 1012
Failure Code [B@BCNS] 1013
Failure Code [B@CRNS] 1014
Failure Code [B@CRZG] 1015
Failure Code [CA115] 1016
Failure Code [CA122] 1017
Failure Code [CA123] 1019
Failure Code [CA131] 1021
Failure Code [CA132] 1023
Failure Code [CA144] 1025
Failure Code [CA145] 1027
Failure Code [CA153] 1029
Failure Code [CA154] 1032
Failure Code [CA187] 1034
Failure Code [CA221] 1036
Failure Code [CA222] 1038
Failure Code [CA227] 1040
Failure Code [CA234] 1041
Failure Code [CA238] 1042
Failure Code [CA239] 1044
Failure Code [CA249] 1046
Failure Code [CA256] 1048
Failure Code [CA271] 1050
Failure Code [CA272] 1052
Failure Code [CA322] 1054
Failure Code [CA323] 1056
Failure Code [CA324] 1058
Failure Code [CA325] 1060
Failure Code [CA331] 1062
Failure Code [CA332] 1064
Failure Code [CA343] 1066
Failure Code [CA351] 1067
Failure Code [CA352] 1068
Failure Code [CA356] 1071
Failure Code [CA357] 1073
Failure Code [CA386] 1076
Failure Code [CA428] 1077
Failure Code [CA429] 1079
Failure Code [CA435] 1081
Failure Code [CA441] 1083
Failure Code [CA442] 1085
Failure Code [CA449] 1086
Failure Code [CA451] 1087
Failure Code [CA452] 1089
Failure Code [CA488] 1091
Failure Code [CA515] 1092
Failure Code [CA516] 1094
Failure Code [CA553] 1096
Failure Code [CA555] 1097
Failure Code [CA556] 1098
Failure Code [CA559] 1099
Failure Code [CA595] 1102
Failure Code [CA687] 1103
Failure Code [CA689] 1105
Failure Code [CA691] 1108
Failure Code [CA692] 1110
Failure Code [CA697] 1112
Failure Code [CA698] 1113
Failure Code [CA731] 1114
Failure Code [CA778] 1116
Failure Code [CA1117] 1121
Failure Code [CA1664] 1122
Failure Code [CA1669] 1125
Failure Code [CA1673] 1126
Failure Code [CA1677] 1127
Failure Code [CA1678] 1128
Failure Code [CA1682] 1129
Failure Code [CA1683] 1133
Failure Code [CA1684] 1135
Failure Code [CA1686] 1137
Failure Code [CA1691] 1138
Failure Code [CA1694] 1141
Failure Code [CA1695] 1144
Failure Code [CA1696] 1145
Failure Code [CA1712] 1147
Failure Code [CA1713] 1150
Failure Code [CA1714] 1152
Failure Code [CA1715] 1153
Failure Code [CA1776] 1154
Failure Code [CA1777] 1157
Failure Code [CA1843] 1160
Failure Code [CA1844] 1162
Failure Code [CA1879] 1165
Failure Code [CA1881] 1168
Failure Code [CA1883] 1170
Failure Code [CA1885] 1174
Failure Code [CA1887] 1176
Failure Code [CA1921] 1178
Failure Code [CA1922] 1181
Failure Code [CA1942] 1186
Failure Code [CA1993] 1187
Failure Code [CA2185] 1190
Failure Code [CA2186] 1192
Failure Code [CA2249] 1194
Failure Code [CA2271] 1195
Failure Code [CA2272] 1198
Failure Code [CA2288] 1201
Failure Code [CA2311] 1202
Failure Code [CA2349] 1203
Failure Code [CA2353] 1206
Failure Code [CA2357] 1208
Failure Code [CA2381] 1209
Failure Code [CA2382] 1212
Failure Code [CA2383] 1215
Failure Code [CA2386] 1218
Failure Code [CA2387] 1220
Troubleshooting Flowchart 1224
Failure Code [CA2555] 1225
Failure Code [CA2556] 1228
Failure Code [CA2637] 1231
Failure Code [CA2639] 1233
Failure Code [CA2771] 1236
Failure Code [CA2777] 1242
Failure Code [CA2976] 1245
Failure Code [CA3133] 1247
Failure Code [CA3134] 1249
Failure Code [CA3135] 1251
Failure Code [CA3142] 1255
Failure Code [CA3143] 1256
Failure Code [CA3144] 1257
Failure Code [CA3146] 1259
Failure Code [CA3147] 1260
Failure Code [CA3148] 1261
Failure Code [CA3151] 1263
Failure Code [CA3165] 1269
Failure Code [CA3229] 1271
Failure Code [CA3231] 1273
Failure Code [CA3232] 1275
Failure Code [CA3235] 1279
Failure Code [CA3239] 1281
Failure Code [CA3241] 1284
Failure Code [CA3242] 1287
Failure Code [CA3251] 1290
Failure Code [CA3253] 1292
Failure Code [CA3254] 1295
Failure Code [CA3255] 1298
Failure Code [CA3256] 1301
Failure Code [CA3311] 1303
Failure Code [CA3312] 1305
Failure Code [CA3313] 1308
Failure Code [CA3314] 1309
Failure Code [CA3315] 1310
Failure Code [CA3316] 1313
Failure Code [CA3317] 1314
Failure Code [CA3318] 1315
Failure Code [CA3319] 1318
Failure Code [CA3321] 1319
Failure Code [CA3322] 1321
Failure Code [CA3419] 1324
Failure Code [CA3421] 1326
Failure Code [CA3497] 1328
Failure Code [CA3498] 1329
Failure Code [CA3543] 1330
Failure Code [CA3545] 1337
Failure Code [CA3547] 1339
Failure Code [CA3558] 1340
Failure Code [CA3559] 1342
Failure Code [CA3562] 1344
Failure Code [CA3563] 1346
Failure Code [CA3567] 1349
Failure Code [CA3568] 1352
Failure Code [CA3571] 1358
Failure Code [CA3572] 1360
Failure Code [CA3574] 1362
Failure Code [CA3575] 1365
Failure Code [CA3577] 1367
Failure Code [CA3578] 1369
Failure Code [CA3582] 1371
Failure Code [CA3583] 1378
Failure Code [CA3596] 1380
Failure Code [CA3649] 1383
Failure Code [CA3681] 1385
Failure Code [CA3682] 1390
Failure Code [CA3713] 1396
Failure Code [CA3717] 1399
Failure Code [CA3718] 1400
Failure Code [CA3725] 1401
Failure Code [CA3741] 1404
Failure Code [CA3748] 1405
Failure Code [CA3751] 1407
Failure Code [CA3755] 1409
Failure Code [CA3866] 1411
Failure Code [CA3867] 1415
Failure Code [CA3868] 1418
Failure Code [CA3899] 1422
Failure Code [CA3911] 1424
Failure Code [CA3912] 1428
Failure Code [CA3932] 1430
Failure Code [CA3933] 1432
Failure Code [CA3934] 1434
Failure Code [CA3935] 1437
Failure Code [CA3936] 1439
Failure Code [CA4151] 1441
Failure Code [CA4152] 1445
Failure Code [CA4155] 1449
Failure Code [CA4156] 1452
Failure Code [CA4157] 1455
Failure Code [CA4158] 1457
Failure Code [CA4159] 1458
Failure Code [CA4161] 1459
Failure Code [CA4162] 1462
Failure Code [CA4163] 1465
Failure Code [CA4164] 1467
Failure Code [CA4165] 1469
Failure Code [CA4166] 1471
Failure Code [CA4168] 1473
Failure Code [CA4169] 1476
Failure Code [CA4171] 1478
Failure Code [CA4249] 1481
Failure Code [CA4251] 1483
Failure Code [CA4259] 1485
Failure Code [CA4261] 1488
Failure Code [CA4277] 1491
Failure Code [CA4281] 1495
Failure Code [CA4459] 1498
Failure Code [CA4461] 1501
Failure Code [CA4658] 1504
Failure Code [CA4731] 1508
Failure Code [CA4732] 1509
Failure Code [CA4739] 1510
Failure Code [CA4768] 1511
Failure Code [CA4769] 1513
Failure Code [CA4842] 1516
Failure Code [CA4952] (Machine with KOMTRAX Terminal) 1520
Failure Code [CA4952] (Machine with Gateway Function Controller) 1522
Failure Code [CA5115] 1524
Failure Code [CA5383] 1527
Failure Code [D130KA] 1529
Failure Code [D130KB] 1532
Failure Code [D130KY] 1534
Failure Code [D19JKZ] 1536
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1539
Failure Code [D811MC] (Machine with Gateway Function Controller) 1540
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1541
Failure Code [D862KA] (Machine with Gateway Function Controller) 1542
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1543
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1545
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1547
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1549
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 1551
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1553
Failure Code [D8G1KT] 1555
Failure Code [D8G6KT] 1556
Failure Code [DAF0MB] 1557
Failure Code [DAF0MC] 1558
Failure Code [DAF8KB] 1559
Failure Code [DAF9KQ] 1561
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1562
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1563
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 1564
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1566
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 1568
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1570
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1572
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1573
Failure Code [DAJ000] 1574
Failure Code [DAJ0KQ] 1575
Failure Code [DAJ0KT] 1576
Failure Code [DAJ0MC] 1577
Failure Code [DAJ1KK] 1578
Failure Code [DAJ2KK] 1580
Failure Code [DAJ5KK] 1582
Failure Code [DAJ6KK] 1585
Failure Code [DAJLKA] (Machine with KOMTRAX Terminal) 1587
Failure Code [DAJLKA] (Machine with Gateway Function Controller) 1589
Failure Code [DAJLKB] (Machine with KOMTRAX Terminal) 1591
Failure Code [DAJLKB] (Machine with Gateway Function Controller) 1593
Failure Code [DAJPMA] 1595
Failure Code [DAJQKR] (Machine with KOMTRAX Terminal) 1596
Failure Code [DAJQKR] (Machine with Gateway Function Controller) 1597
Failure Code [DAJRKR] 1598
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 1599
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1604
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal) 1609
Failure Code [DB2RKR] (Machine with Gateway Function Controller) 1614
Failure Code [DD12KA] 1619
Failure Code [DD12KB] 1621
Failure Code [DD13KA] 1623
Failure Code [DD13KB] 1625
Failure Code [DD14KA] 1627
Failure Code [DD14KB] 1629
Failure Code [DDKAKA] 1631
Failure Code [DDKAKB] 1633
Failure Code [DDKFL4] 1635
Failure Code [DDKGL4] 1637
Failure Code [DDKHKA] 1639
Failure Code [DDKHKB] 1641
Failure Code [DDNLKA] 1643
Failure Code [DDNLKB] 1645
Failure Code [DDP6KA] 1647
Failure Code [DDP6KB] 1650
Failure Code [DDP6MA] 1652
Failure Code [DDU1FS] 1654
Failure Code [DDU1KA] 1656
Failure Code [DDU1KY] 1659
Failure Code [DFA4KX] 1661
Failure Code [DFA4KZ] 1662
Failure Code [DFA4L8] 1663
Failure Code [DFA5KA] 1664
Failure Code [DFA5KB] 1667
Failure Code [DFA6KA] 1670
Failure Code [DFA6KB] 1673
Failure Code [DFA7KX] 1676
Failure Code [DFA7KZ] 1677
Failure Code [DFA7L8] 1678
Failure Code [DFA8KA] 1679
Failure Code [DFA8KB] 1682
Failure Code [DFA9KA] 1685
Failure Code [DFA9KB] 1688
Failure Code [DGS1KA] 1691
Failure Code [DGS1KX] 1694
Failure Code [DH21KA] 1695
Failure Code [DH21KB] 1697
Failure Code [DHA4KA] 1699
Failure Code [DHAAMA] 1701
Failure Code [DHACMA] 1703
Failure Code [DHH7KA] 1705
Failure Code [DHH7KB] 1708
Failure Code [DHH8KA] 1710
Failure Code [DHH8KB] 1713
Failure Code [DHH9KA] 1715
Failure Code [DHH9KB] 1718
Failure Code [DHHAKA] 1720
Failure Code [DHHAKB] 1723
Failure Code [DK30KA] 1725
Failure Code [DK30KB] 1728
Failure Code [DK30KX] 1730
Failure Code [DK30KZ] 1731
Failure Code [DK30L8] 1732
Failure Code [DK31KA] 1733
Failure Code [DK31KB] 1736
Failure Code [DK40KA] 1738
Failure Code [DK40KB] 1741
Failure Code [DK55KX] 1743
Failure Code [DK55KZ] 1744
Failure Code [DK55L8] 1745
Failure Code [DK56KA] 1746
Failure Code [DK56KB] 1749
Failure Code [DK57KA] 1751
Failure Code [DK57KB] 1754
Failure Code [DLM0KX] 1756
Failure Code [DLM1KA] 1757
Failure Code [DLM1KB] 1759
Failure Code [DLM1MA] 1761
Failure Code [DLM2KA] 1762
Failure Code [DLM2KB] 1764
Failure Code [DLM2MA] 1766
Failure Code [DLM3KA] 1767
Failure Code [DLM3KB] 1769
Failure Code [DLM3MB] 1771
Failure Code [DN21FS] 1772
Failure Code [DR21KX] 1774
Failure Code [DR31KX] 1775
Failure Code [DV20KB] 1776
Failure Code [DW4BKA] 1778
Failure Code [DW4BKB] 1780
Failure Code [DW4BKY] 1782
Failure Code [DW7BKA] 1784
Failure Code [DW7BKB] 1786
Failure Code [DW7EKA] 1788
Failure Code [DW7EKB] 1790
Failure Code [DW7EKY] 1792
Failure Code [DWN5KA] 1794
Failure Code [DWN5KB] 1796
Failure Code [DWN5KY] 1798
Failure Code [DXA4KA] 1800
Failure Code [DXA4KB] 1802
Failure Code [DXA4KY] 1804
Failure Code [DXA5KA] 1806
Failure Code [DXA5KB] 1808
Failure Code [DXA5KY] 1810
Failure Code [DXA6KA] 1812
Failure Code [DXA6KB] 1814
Failure Code [DXA6KY] 1816
Failure Code [DXA7KA] 1818
Failure Code [DXA7KB] 1820
Failure Code [DXA7KY] 1822
Failure Code [DXHRKA] 1824
Failure Code [DXHRKB] 1826
Failure Code [DXHRKY] 1828
Failure Code [DXHSKA] 1830
Failure Code [DXHSKB] 1832
Failure Code [DXHSKY] 1834
Failure Code [DXHTKA] 1836
Failure Code [DXHTKB] 1838
Failure Code [DXHTKY] 1840
Failure Code [DXHUKA] 1842
Failure Code [DXHUKB] 1844
Failure Code [DXHUKY] 1846
Failure Code [DXJ4KA] 1848
Failure Code [DXJ4KB] 1850
Failure Code [DXJCKA] 1852
Failure Code [DXJCKB] 1854
Failure Code [DXJCKY] 1856
Failure Code [DXJDKA] 1858
Failure Code [DXJDKB] 1860
Failure Code [DXJDKY] 1862
Failure Code [DXK1KA] 1864
Failure Code [DXK1KB] 1866
Failure Code [DXK1KY] 1868
Failure Code [DXK2KA] 1870
Failure Code [DXK2KB] 1872
Failure Code [DXK2KY] 1874
Failure Code [F313KA] 1876
Failure Code [F313KB] 1877
Failure Code [F318KB] 1878
Failure Code [F318KY] 1879
Troubleshooting of Electrical System (E-Mode) 1880
Engine Does Not Start (Engine Does Not Crank) 1880
Manual Preheating System Does Not Operate 1887
Automatic Preheating System Does Not Operate 1890
While Preheating is in Operation, Preheating Monitor Does Not Come On 1892
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1894
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 1898
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1899
Charge Level Monitor Comes On in Red While Engine is in Operation 1900
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1901
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1902
HST Charge Pressure Monitor Comes On in Red While Engine Runs 1903
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1904
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs 1905
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1906
Fuel Gauge Does Not Show Normally 1907
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1910
Operation Mode Does Not Change 1911
When You Operate Customize Switch Does Not Show Customize Screen 1912
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 1913
Service Meter is Not Shown While Starting Switch is in OFF Position 1914
Service Mode Cannot be Selected 1915
Work Equipment Does Not Operate 1916
Foot Heater Does Not Operate 1918
Horn Does Not Sound 1924
Horn Does Not Stop 1926
Backup Alarm Does Not Sound 1927
Backup Alarm Does Not Stop Operation 1928
Headlamp Does Not Come On 1929
Rear Lamp Does Not Come On 1933
No Wiper Operates 1936
Front Wiper Does Not Operate 1938
Rear Wiper Does Not Operate 1940
Left Door Wiper Does Not Operate 1942
Right Door Wiper Does Not Operate 1946
Front Washer Does Not Operate 1950
Rear Washer Does Not Operate 1952
Left Door Washer Does Not Operate 1954
Right Door Washer Does Not Operate 1956
KOMTRAX System Does Not Operate Correctly 1958
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1959
Information Shown in Troubleshooting Table (H-Mode) 1959
Failure Mode and Cause Table 1960
R H and L H Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) 1966
R H or L H Track Cannot Travel FORWARD and Reverse (One of R H or L H Travel Systems Cannot Operate) 1968
R H or L H Track Cannot Travel Forward or Reverse (Only One of the Travel Systems Cannot Operate in One Direction) 1970
Travel Speed or Power is Low 1972
Speed Range Does Not Change 1974
Shock is Large When Machine Moves Off or Stops 1975
Travel Deviation is Large 1976
Machine Drift on a Slope is Large 1979
Engine Speed Drops Largely or Engine Stops 1981
Unusual Noise is Heard from Around HST Pump or Motor 1983
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 1985
All Work Equipment Do Not Operate 1987
All Work Equipment Speed or Power is Low 1989
Blade Lift Speed or Power is Low 1990
Blade Tilt Speed or Power is Low 1992
Blade Angle Speed or Power is Low 1993
Time Lag of Blade Lift is Large 1994
Hydraulic Drift of Blade Lift is Large 1995
Hydraulic Drift of Tilted Blade is Large 1996
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 1997
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 1998
Unusual Noise is Heard from Around Fan 2000
Troubleshooting of Engine (S-Mode) 2001
Information Shown in Troubleshooting Table (S-Mode) 2001
Engine Does Not Crank When Starting Switch is Turned to Start Position 2002
Engine Cranks but No Exhaust Smoke Comes Out 2003
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2004
Engine Startability is Unsatisfactory 2006
Engine Does Not Pick Up Smoothly 2008
Engine Stops During Operation 2010
Engine Does Not Rotate Smoothly 2012
Engine Lacks Output (or Lacks Power) 2013
KDPF Becomes Clogged in a Short Time 2015
Engine Oil Consumption is Excessive 2017
Engine Oil Becomes Dirty Quickly 2018
Fuel Consumption is Excessive 2019
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2020
Engine Oil Pressure Drops 2021
Fuel Mixes Into Engine Oil 2023
Water Mixes Into Engine Oil (Milky) 2024
Coolant Temperature Increases Too High (Overheat) 2025
Unusual Noise is Heard 2026
Vibration is Excessive 2027
Air Cannot be Bled from Fuel Circuit 2028
Active Regeneration is Done Frequently 2029
Active Regeneration Continues Long 2031
White Smoke is Exhausted During Active Regeneration 2032
DEF Consumption is Excessive 2033
There is an Unusual Smell (Irritating Odor) 2035
Foreign Materials Enter DEF (DEF Increases) 2036
50 Disassembly and Assembly 2037
Table of Contents 2038
Precautions Before Work 2043
Abbreviation List 2044
Related Information on Disassembly and Assembly 2050
How to Read This Manual 2050
Coating Materials List 2051
Special Tool List 2056
Sketches of Special Tools 2075
Engine and Cooling System 2088
Remove and Install Supply Pump Assembly 2088
Remove Supply Pump Assembly 2088
Install Supply Pump Assembly 2094
Remove and Install Injector Assembly 2101
How to Remove Injector Assembly 2101
How to Install Injector Assembly 2108
Remove and Install Cylinder Head Assembly 2118
How to Remove Cylinder Head Assembly 2118
How to Install Cylinder Head Assembly 2130
Remove and Install EGR Valve Assembly 2148
Remove EGR Valve Assembly 2148
Install EGR Valve Assembly 2149
Remove and Install EGR Cooler Assembly 2151
How to Remove EGR Cooler Assembly 2151
How to Install EGR Cooler Assembly 2153
Remove and Install Starter Assembly 2156
Remove Starting Motor Assembly 2156
Install Starting Motor Assembly 2158
Remove and Install Alternator Belt 2160
Remove Alternator Belt 2160
Install Alternator Belt 2161
Remove and Install Automatic Tensioner 2163
Remove Automatic Tensioner 2163
Install Automatic Tensioner 2163
Remove and Install Radiator Assembly 2164
How to Remove Radiator Assembly 2164
How to Install Radiator Assembly 2167
Remove and Install Hydraulic Oil Cooler Assembly 2171
How to Remove Hydraulic Oil Cooler Assembly 2171
How to Install Hydraulic Oil Cooler Assembly 2173
Remove and Install Aftercooler Assembly 2176
Remove Aftercooler Assembly 2176
Install Aftercooler Assembly 2179
Remove and Install Cooling Fan Drive Assembly 2183
Remove Cooling Fan Drive Assembly 2183
Install Cooling Fan Drive Assembly 2186
Remove and Install Cooling Fan Motor Assembly 2190
Remove Cooling Fan Motor Assembly 2190
Install Cooling Fan Motor Assembly 2193
Remove and Install Engine and HST Pump Assembly 2197
Remove Engine and HST Pump Assembly 2197
Install Engine and HST Pump Assembly 2206
Remove and Install Engine Front Oil Seal 2217
How to Remove Engine Front Oil Seal 2217
How to Install Engine Front Oil Seal 2218
Remove and Install Engine Rear Oil Seal 2220
How to Remove Engine Rear Oil Seal 2220
How to Install Engine Rear Oil Seal 2222
Remove and Install Engine Hood Assembly 2225
How to Remove Engine Hood Assembly 2225
How to Install Engine Hood Assembly 2228
Remove and Install Fuel Tank Assembly 2232
Remove Fuel Tank Assembly 2232
Install Fuel Tank Assembly 2238
Remove and Install DEF Tank Assembly 2244
How to Remove DEF Tank Assembly 2244
How to Install DEF Tank Assembly 2250
Remove and Install DEF Tank Sensor Flange Assembly 2256
How to Remove DEF Tank Sensor Flange Assembly 2256
How to Install DEF Tank Sensor Flange Assembly 2257
Remove and Install DEF Tank Sensor 2260
Remove DEF Tank Sensor 2260
Install DEF Tank Sensor 2261
Remove and Install DEF Tank Strainer 2268
Remove DEF Tank Strainer 2268
Install DEF Tank Strainer 2269
Remove and Install KDPF Assembly 2270
How to Remove KDPF Assembly 2271
How to Install KDPF Assembly 2274
Disassemble and Assemble KDPF Assembly 2277
Disassemble KDPF Assembly 2277
Assemble KDPF Assembly 2280
Remove and Install SCR Assembly 2287
How to Remove SCR Assembly 2287
How to Install SCR Assembly 2289
Remove and Install KDPF and SCR Assembly 2293
How to Remove KDPF and SCR Assembly 2294
Install KDPF and SCR Assembly 2300
Remove and Install KCCV Assembly 2307
Remove KCCV Assembly 2307
Install KCCV Assembly 2309
Remove and Install VGT Assembly 2311
How to Remove VGT Assembly 2311
How to Install VGT Assembly 2313
Remove and Install DEF Mixing Tube 2316
Remove DEF Mixing Tube 2316
Install DEF Mixing Tube 2318
Remove and Install DEF Injector 2322
Remove DEF Injector 2322
Install DEF Injector 2325
Remove and Install DEF Pump 2329
Remove DEF Pump 2329
Install DEF Pump 2332
Remove and Install DEF Hose 2335
Remove DEF Hose 2335
Install DEF Hose 2339
Remove and Install Air Cleaner Assembly 2345
Remove Air Cleaner Assembly 2345
Install Air Cleaner Assembly 2347
Remove and Install Air Conditioner Compressor Assembly 2350
Remove Air Conditioner Compressor Assembly 2350
How to Install Air Conditioner Compressor Assembly 2351
Remove and Install Air Conditioner Condenser Assembly 2353
How to Remove Air Conditioner Condenser Assembly 2353
How to Install Air Conditioner Condenser Assembly 2357
Power Train 2361
Remove and Install Damper Assembly 2361
How to Remove Damper Assembly 2361
How to Install Damper Assembly 2362
Remove and Install HST Pump Assembly 2364
Remove HST Pump Assembly 2364
Install HST Pump Assembly 2366
Remove and Install HST Motor and Final Drive Assembly 2368
Remove HST Motor and Final Drive Assembly 2368
Install HST Motor and Final Drive Assembly 2371
Disassemble and Assemble Final Drive Assembly 2374
Disassemble Final Drive Assembly 2375
Assemble Final Drive Assembly 2380
Undercarriage and Frame 2389
Remove and Install Track Frame Assembly 2389
Remove Track Frame Assembly 2389
Install Track Frame Assembly 2393
Remove and Install Idler Assembly 2398
Remove Idler Assembly 2398
Install Idler Assembly 2400
Disassemble and Assemble Idler Assembly 2402
Disassemble Idler Assembly 2402
Assemble Idler Assembly 2404
Remove and Install Recoil Spring Assembly 2409
Remove Recoil Spring Assembly 2409
Install Recoil Spring Assembly 2410
Disassemble and Assemble Recoil Spring Assembly 2411
Disassemble Recoil Spring Assembly 2411
Assemble Recoil Spring Assembly 2414
Remove and Install Track Roller Assembly 2417
Remove Track Roller Assembly 2417
Install Track Roller Assembly 2418
Disassemble and Assemble Track Roller Assembly 2421
Disassemble Track Roller Assembly 2421
Assemble Track Roller Assembly 2423
Remove and Install Carrier Roller Assembly 2427
Remove Carrier Roller Assembly 2427
Install Carrier Roller Assembly 2428
Disassemble and Assemble Carrier Roller Assembly 2430
Disassemble Carrier Roller Assembly 2430
Assemble Carrier Roller Assembly 2431
Remove and Install Pivot Shaft Assembly 2434
Remove Pivot Shaft Assembly 2434
Install Pivot Shaft Assembly 2435
Separate and Connect Track Assembly 2437
Examine Before Separation of Track Assembly 2437
Separate Track Assembly (Standard) 2438
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2439
Install Track Assembly 2440
Separate and Connect PLUS Type Track Assembly 2442
Separate PLUS Type Track Assembly Generally 2442
Install PLUS Type Track Assembly 2442
Disassemble and Assemble Track Assembly Generally 2444
How to Disassemble Full Track Shoes Assembly 2444
How to Assemble Full Track Shoes Assembly 2449
Disassemble and Assemble PLUS Type Track Assembly Generally 2462
Disassemble PLUS Type Track Assembly Generally 2463
How to Assemble PLUS Type Track Shoes Assembly Generally 2464
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2479
Disassemble One Track Link Assembly in Field (Track Assembly) 2480
Assemble One Track Link Assembly in Field (Track Assembly) 2481
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2488
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2489
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2491
Remove and Install Equalizer Bar Assembly 2495
Remove Equalizer Bar Assembly 2495
Install Equalizer Bar Assembly 2497
Remove and Install Equalizer Bar Side Bushing 2500
How to Remove Equalizer Bar Side Bushings 2500
How to Install Equalizer Bar Side Bushings 2500
Remove and Install Segment Teeth 2502
Remove Segment Teeth 2502
Install Segment Teeth 2503
Hydraulic System 2504
Remove and Install Hydraulic Tank Assembly 2504
Remove Hydraulic Tank Assembly 2505
How to Install Hydraulic Tank Assembly 2509
Remove and Install Control Valve Assembly 2514
How to Remove Control Valve Assembly 2514
How to Install Control Valve Assembly 2519
Work Equipment 2524
Remove and Install Blade Assembly 2524
Remove Blade Assembly 2524
Install Blade Assembly 2526
Remove and Install Work Equipment Assembly 2529
Remove Work Equipment Assembly 2529
Install Work Equipment Assembly 2531
How to Disassemble and Assemble Work Equipment Cylinder Assembly 2533
How to Disassemble Work Equipment Cylinder Assembly 2534
How to Assemble Work Equipment Cylinder Assembly 2535
Remove and Install U-Frame Assembly 2539
Remove U-Frame Assembly 2539
Install U-Frame Assembly 2541
CAB Related Parts 2543
Remove and Install Operator Cab Assembly 2543
How to Remove Operator Cab Assembly 2543
Install Operator CAB Assembly 2550
Remove and Install Operator Cab Glass (Adhered Glass) 2557
Remove Operator CAB Glass (Adhered Glass) 2559
Install Operator CAB Glass (Adhered Glass) 2559
Remove and Install Air Conditioner Unit Assembly 2565
Remove Air Conditioner Unit Assembly 2565
Install Air Conditioner Unit Assembly 2571
Remove and Install Receiver Drier 2578
Remove Receiver Drier 2578
Install Receiver Drier 2579
Remove and Install Operator Seat 2582
Remove Operator’s Seat 2582
Install Operator’s Seat 2583
How to Remove and Install Seat Belt 2584
How to Remove Seat Belt 2584
How to Install Seatbelt 2584
Remove and Install Foot Heater Assembly 2586
Remove Foot Heater Assembly 2586
Install Foot Heater Assembly 2588
Disassemble and Assemble Foot Heater Assembly 2591
Disassemble Foot Heater Assembly 2591
Assemble Foot Heater Assembly 2592
Electrical System 2593
Remove and Install Engine Controller Assembly 2593
Remove Engine Controller Assembly 2593
Install Engine Controller Assembly 2595
Remove and Install HST Controller Assembly 2598
Remove HST Controller Assembly 2598
How to Install HST Controller Assembly 2599
Remove and Install Machine Monitor Assembly 2600
Remove Machine Monitor Assembly 2600
Install Machine Monitor Assembly 2601
Remove and Install Mass Air Flow and Temperature Sensor 2603
How to Remove Mass Air Flow and Temperature Sensor 2603
How to Install Mass Air Flow and Temperature Sensor 2605
Remove and Install KCCV Crankcase Pressure Sensor 2606
How to Remove KCCV Crankcase Pressure Sensor 2606
How to Install KCCV Crankcase Pressure Sensor 2608
Remove and Install SCR Temperature Sensor 2610
Remove SCR Temperature Sensor 2610
Install SCR Temperature Sensor 2611
Remove and Install KOMTRAX Terminal Assembly 2613
Remove KOMTRAX Terminal Assembly 2613
Install KOMTRAX Terminal Assembly 2614
Remove and Install Gateway Function Controller Assembly 2615
How to Remove Gateway Function Controller Assembly 2615
How to Install Gateway Function Controller Assembly 2616
Remove and Install Communication Terminal 2617
How to Remove Communication Terminal 2617
How to Install Communication Terminal 2620
60 Maintenance Standard 2623
Table of Contents 2624
Abbreviation List 2625
Engine and Cooling System 2631
Maintenance Standard for Engine Mount 2631
Maintenance Standard for Damper 2632
Maintenance Standard for Cooling System 2633
Maintenance Standard for Cooling Fan Motor 2635
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 2637
Power Train 2638
Maintenance Standard for HST Pump 2638
Maintenance Standard for EPC Valve of HST Pump 2639
Maintenance Standard for Tow Receiving Valve of HST Pump 2640
Maintenance Standard for HST Charge Pump 2641
Maintenance Standard for HST Motor 2643
Maintenance Standard for Final Drive 2644
Maintenance Standard for Sprocket for Conventional Type Track Shoes 2646
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2647
Maintenance Standard for Sprocket for PLUS Type Track Shoes 2649
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2650
Undercarriage and Frame 2652
Maintenance Standard for Suspension 2652
Maintenance Standard for Track Frame and Idler Cushion 2654
Maintenance Standard for Idler 2656
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2658
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2659
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2660
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2661
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2662
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 2663
Maintenance Standard for Conventional Type Track Shoes 2664
Maintenance Standard for PLUS Type Track Shoes 2666
Maintenance Standard for Single Shoes 2668
Maintenance Standard for Swamp Shoes 2669
Hydraulic System 2670
Maintenance Standard for Hydraulic Tank 2670
Maintenance Standard for Work Equipment and Cooling Fan Pump 2671
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump 2672
Maintenance Standard for Control Valve 2674
Maintenance Standard for Ripper PPC Valve 2681
Maintenance Standard for 5-Spool EPC and Solenoid Valve 2683
Maintenance Standard for EPC Valve 2684
Maintenance Standard for Angle Control EPC Valve 2685
Maintenance Standard for Quick Drop Valve 2686
Work Equipment 2688
Maintenance Standard for Front Work Equipment 2688
Maintenance Standard for Cutting Edge and End Bit 2691
Maintenance Standard for Blade Lift Cylinder 2692
Maintenance Standard for Blade Tilt Cylinder 2693
Maintenance Standard for Blade Angle Cylinder 2694
Maintenance Standard for Fixed Multi-Shank Ripper 2695
Maintenance Standard for Ripper Lift Cylinder 2697
CAB Related Parts 2698
Maintenance Standard for CAB Mount 2698
Electrical System 2699
Maintenance Standard for Steering Electric Lever 2699
80 Appendix 2701
Table of Contents 2702
Precautions Before Work 2703
Abbreviation List 2704
Air Conditioner System 2710
Precautions for Refrigerant 2710
Air Conditioner Component 2711
Specifications of Air Conditioner 2714
Structure and Function of Refrigeration Cycle 2715
Outline of Refrigeration Cycle 2716
Component Parts of Air Conditioner System 2718
Air Conditioner Unit 2718
Configuration Diagram of Air Conditioner Unit 2718
Function of Air Conditioner Unit 2719
Component Parts of Air Conditioner Unit 2720
Function of Evaporator as Air Conditioner Unit Component 2720
Function of Heater Core as Air Conditioner Unit Component 2720
Function of Thermostat as Air Conditioner Unit Component 2720
Structure of Expansion Valve as Air Conditioner Unit Component 2721
Function of Expansion Valve as Air Conditioner Unit Component 2721
Operate Expansion Valve as Air Conditioner Unit Component 2721
Function of Dual Pressure Switch 2722
Function of Pressure Switch 2722
Compressor 2723
Structure of Compressor 2723
Specifications of Compressor 2723
Function of Compressor 2723
Condenser 2724
Structure of Condenser 2724
Specifications of Condenser 2724
Function of Condenser 2725
Receiver Drier 2726
Structure of Receiver Dryer 2726
Specifications of Receiver Dryer 2726
Function of Receiver Dryer 2726
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2728
Circuit Diagram of Air Conditioner 2731
System Diagram of Air Conditioner 2732
Control Function of Air Conditioner 2733
Locations of Air Conditioner Parts and Layout of Connectors 2734
Examine Relay 2738
How to Examine Relay 2738
Air Conditioner Troubleshooting Chart 1 2740
Air Conditioner Troubleshooting Chart 2 2741
Information Shown in Troubleshooting Table 2744
Troubleshooting for Condenser Fan 2745
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2748
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2752
Troubleshooting for Temperature Control Function 2755
Troubleshooting by Gauge Pressure 2759
Connect Service Tool 2761
How to Connect Service Tool 2761
Precautions for Disconnection and Connection of Air Conditioner Piping 2762
Handle Compressor Oil 2764
90 Circuit Diagrams 2767
Table of Contents 2768
Abbreviation List 2769
Hydraulic Circuit Diagram 2775
Symbols Used in Hydraulic Circuit Diagram 2775
Hydraulic Circuit Diagram 2779
Electrical Circuit Diagram 2781
Symbols Used in Electric Circuit Diagram 2781
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/14) 2785
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/14) 2787
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/14) 2789
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/14) 2791
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/14) 2793
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/14) 2795
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/14) 2797
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/14) 2799
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/14) 2801
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/14) 2803
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/14) 2805
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (12/14) 2807
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (13/14) 2809
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (14/14) 2811
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/16) 2813
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/16) 2815
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/16) 2817
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/16) 2819
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/16) 2821
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/16) 2823
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/16) 2825
Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/16) 2827
Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/16) 2829
Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/16) 2831
Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/16) 2833
Electrical Circuit Diagram (Machine with Gateway Function Controller) (12/16) 2835
Electrical Circuit Diagram (Machine with Gateway Function Controller) (13/16) 2837
Electrical Circuit Diagram (Machine with Gateway Function Controller) (14/16) 2839
Electrical Circuit Diagram (Machine with Gateway Function Controller) (15/16) 2841
Electrical Circuit Diagram (Machine with Gateway Function Controller) (16/16) 2843
INDEX 2845
IMAGES PREVIEW OF THE MANUAL:
S.V 27/12/24
