Komatsu D61EX-24E0 D61PX-24E0 Bulldozer Shop Manual SEN06797-01 PDF

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Komatsu D61EX-24E0 D61PX-24E0 Bulldozer Shop Manual SEN06797-01 – PDF DOWNLOAD

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Komatsu D61EX-24E0 D61PX-24E0 Bulldozer Shop Manual SEN06797-01 – PDF DOWNLOAD 

Language : English
Pages : 2722
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D61EX-24E0 D61PX-24E0 Bulldozer Shop Manual SEN06797-01 – PDF DOWNLOAD 

SERIAL NUMBERS

D61EX-41275 and up
D61PX-41275 and up

Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu D61EX-24E0 D61PX-24E0 Bulldozer Shop Manual SEN06797-01 – 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-24E0 101
SPECIFICATION DRAWING: D61PX-24E0 103
SPECIFICATIONS 105
SPECIFICATIONS: D61EX-24E0 105
SPECIFICATIONS: D61PX-24E0 110
WEIGHT TABLE 114
WEIGHT TABLE: D61EX-24E0 114
WEIGHT TABLE: D61PX-24E0 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
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 210
FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 210
COMPONENT PARTS OF CONTROL SYSTEM 211
MACHINE MONITOR 211
GATEWAY FUNCTION CONTROLLER 226
COMMUNICATION TERMINAL 229
HST CONTROLLER 231
ENGINE CONTROLLER 235
DECELERATOR AND BRAKE POTENTIOMETER 242
HYDRAULIC SYSTEM 244
LAYOUT DRAWING OF HYDRAULIC SYSTEM 244
CLSS 245
STRUCTURE OF CLSS 245
FUNCTION OF CLSS 246
COMPONENT PARTS OF HYDRAULIC SYSTEM 248
HYDRAULIC TANK 248
WORK EQUIPMENT AND COOLING FAN PUMP 250
LS VALVE 258
PC VALVE 259
CONTROL VALVE 262
POWER TRAIN SYSTEM 283
LAYOUT DRAWING OF HST SYSTEM 283
OPERATION OF HST SYSTEM 284
STEERING AND BRAKE CONTROL SYSTEM 286
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 286
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 286
HST CONTROL SYSTEM 288
HST CONTROL SYSTEM DIAGRAM 288
GEAR SHIFT CONTROL FUNCTION 289
ENGINE LOW SPEED MATCHING CONTROL FUNCTION 293
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION 293
DECELERATION AND BRAKE CONTROL FUNCTION 295
GEAR SHIFT CONTROL FUNCTION BY LOAD 296
TURN CONTROL FUNCTION 296
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 297
PARKING BRAKE CONTROL SYSTEM 299
PARKING BRAKE CONTROL SYSTEM DIAGRAM 299
FUNCTION OF PARKING BRAKE CONTROL SYSTEM 300
OPERATION OF PARKING BRAKE CONTROL SYSTEM 301
COMPONENT PARTS OF POWER TRAIN SYSTEM 302
HST PUMP 302
HST CHARGE PUMP 319
HST MOTOR 320
FINAL DRIVE 332
ELECTRIC STEERING CONTROL LEVER 336
WORK EQUIPMENT SYSTEM 339
WORK EQUIPMENT CONTROL 339
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 339
FUNCTION OF WORK EQUIPMENT CONTROL 340
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 342
LAYOUT OF FIXED MULTI-SHANK RIPPER 343
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 344
RIPPER PPC VALVE 344
5-PORT VALVE OF EPC AND SOLENOID 348
PILOT CIRCUIT ACCUMULATOR 354
ANGLE CONTROL EPC VALVE 355
QUICK DROP VALVE 358
PISTON VALVE 360
ELECTRIC BLADE CONTROL LEVER 361
UNDERCARRIAGE AND FRAME 363
MAIN FRAME 363
STRUCTURE OF MAIN FRAME 363
SUSPENSION 364
STRUCTURE OF SUSPENSION 364
SPECIFICATIONS OF SUSPENSION 365
FUNCTION OF SUSPENSION 366
TRACK FRAME AND IDLER CUSHION 367
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 367
FUNCTION OF TRACK FRAME AND IDLER CUSHION 368
WORK EQUIPMENT 370
STRUCTURE OF FRONT WORK EQUIPMENT 370
STRUCTURE OF FIXED MULTI-SHANK RIPPER 371
CAB AND ITS ATTACHMENTS 372
ROPS CAB 372
STRUCTURE OF ROPS CAB 372
FUNCTION OF ROPS CAB 373
CAB MOUNT 374
STRUCTURE OF CAB MOUNT 374
FUNCTION OF CAB MOUNT 374
20 STANDARD VALUE TABLE 375
CONTENTS 376
ABBREVIATION LIST 377
STANDARD VALUE TABLE FOR ENGINE 383
STANDARD VALUE TABLE FOR ENGINE: D61EX-24E0 383
STANDARD VALUE TABLE FOR ENGINE: D61PX-24E0 387
STANDARD VALUE TABLE FOR MACHINE 391
STANDARD VALUE TABLE FOR MACHINE: D61EX-24E0 391
STANDARD VALUE TABLE FOR MACHINE: D61PX-24E0 407
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 423
30 TESTING AND ADJUSTING 425
CONTENTS 426
ABBREVIATION LIST 429
RELATED INFORMATION ON TESTING AND ADJUSTING 435
TOOLS FOR TESTING AND ADJUSTING 435
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 442
ENGINE AND COOLING SYSTEM 443
TEST ENGINE SPEED 443
METHOD FOR TESTING ENGINE SPEED 443
TEST BOOST PRESSURE 446
METHOD FOR TESTING BOOST PRESSURE 446
TEST EXHAUST GAS COLOR 448
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 448
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 450
TEST AND ADJUST VALVE CLEARANCE 452
METHOD FOR TESTING VALVE CLEARANCE 452
METHOD FOR ADJUSTING VALVE CLEARANCE 453
TEST COMPRESSION PRESSURE 454
METHOD FOR TESTING COMPRESSION PRESSURE 454
TEST BLOWBY PRESSURE 459
METHOD FOR TESTING BLOWBY PRESSURE 459
TEST ENGINE OIL PRESSURE 462
METHOD FOR TESTING ENGINE OIL PRESSURE 462
TEST EGR VALVE AND VGT OIL PRESSURE 463
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 463
TEST FUEL PRESSURE 465
METHOD FOR TESTING FUEL PRESSURE 466
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 471
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 472
BLEEDING AIR FROM FUEL SYSTEM 478
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 478
TEST FUEL CIRCUIT FOR LEAKAGE 479
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 479
HANDLE CYLINDER CUT-OUT MODE OPERATION 481
HANDLE NO-INJECTION CRANKING OPERATION 482
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 483
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 483
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 484
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 484
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 485
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 485
TEST ALTERNATOR BELT 486
METHOD FOR REMOVING ALTERNATOR BELT 486
TEST AUTOMATIC TENSIONER 488
METHOD FOR TESTING AUTOMATIC TENSIONER 488
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 490
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 490
TEST SCR RELATED FUNCTIONS 491
TEST AdBlue/DEF PUMP RAISED PRESSURE 495
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 498
TEST AdBlue/DEF LINE HEATER RELAY 1 503
TEST AdBlue/DEF LINE HEATER RELAY 2 506
TEST AdBlue/DEF PUMP HEATER RELAY 509
TEST AdBlue/DEF TANK HEATER VALVE 513
TEST DENITRATION EFFICIENCY OF SCR 517
CLEAN AdBlue/DEF TANK 520
METHOD FOR CLEANING AdBlue/DEF TANK 520
CLEAN AdBlue/DEF PUMP 524
CLEAN AdBlue/DEF PUMP 524
CLEAN AdBlue/DEF TANK MOUNTING PORTION 530
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 530
POWER TRAIN 531
TEST AND ADJUST HST OIL PRESSURE 531
METHOD FOR TESTING HST OIL PRESSURE 531
METHOD FOR ADJUSTING HST OIL PRESSURE 534
BLEED AIR FROM HST PUMP 536
METHOD FOR BLEEDING AIR FROM HST PUMP 536
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP 536
TEST OUTLET PRESSURE OF SOLENOID VALVE 538
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 538
TEST TRAVEL DEVIATION 543
METHOD FOR TESTING TRAVEL DEVIATION 543
TEST BRAKE PERFORMANCE SIMPLY 545
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 545
TEST AND ADJUST DECELERATION/BRAKE PEDAL 546
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 546
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 548
ADJUST PARKING BRAKE LEVER 550
METHOD FOR ADJUSTING PARKING BRAKE LEVER 550
MOVE MACHINE WHEN IT CANNOT TRAVEL 552
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 552
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT 554
UNDERCARRIAGE AND FRAME 556
CHECK AND ADJUST IDLER CLEARANCE 556
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE 556
TESTING SPROCKET WEAR 557
METHOD FOR TESTING SPROCKET WEAR 557
TEST AND ADJUST TRACK TENSION 558
METHOD FOR TESTING TRACK TENSION 558
METHOD FOR ADJUSTING TRACK TENSION 558
HYDRAULIC SYSTEM 560
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 560
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 560
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 561
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 561
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 562
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 564
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 564
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 565
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 566
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE 566
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 568
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 568
TEST COOLING FAN SPEED 569
METHOD FOR TESTING COOLING FAN SPEED 569
TEST COOLING FAN CIRCUIT OIL PRESSURE 570
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 570
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 572
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 572
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 572
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 573
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 574
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 574
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 577
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 577
WORK EQUIPMENT 578
ADJUST WORK EQUIPMENT LOCK LEVER 578
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 578
ELECTRICAL SYSTEM 580
SET AND OPERATE MACHINE MONITOR 580
OPERATOR MODE 584
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 584
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 584
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 585
CHECKING FUNCTION OF SERVICE METER 585
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 585
SERVICE MODE 588
SERVICE MODE 588
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 589
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 596
ABNORMALITY RECORD MENU 606
METHOD FOR CONFIRMING MAINTENANCE RECORD 610
METHOD FOR OPERATING MAINTENANCE MODE SETTING 611
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 615
DEFAULT MENU 617
DIAGNOSTIC TESTS MENU 625
ADJUSTMENT MENU 634
METHOD FOR PERFORMING NO-INJECTION CRANKING 689
KOMTRAX SETTINGS MENU 692
METHOD FOR DISPLAYING SERVICE MESSAGE 694
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 696
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 702
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 702
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 708
ADJUST REARVIEW CAMERA ANGLE 710
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 710
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 711
HANDLE BATTERY DISCONNECT SWITCH 712
TEST DIODES 713
METHOD FOR TESTING DIODE USING DIGITAL TESTER 713
METHOD FOR TESTING DIODE USING ANALOG TESTER 713
Pm CLINIC 714
Pm CLINIC SERVICE 714
Pm CLINIC CHECK SHEET: D61EX-24E0 716
Pm CLINIC CHECK SHEET: D61PX-24E0 723
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EX-24E0 730
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PX-24E0 733
40 TROUBLESHOOTING 737
CONTENTS 738
ABBREVIATION LIST 748
RELATED INFORMATION ON TROUBLESHOOTING 754
GENERAL TROUBLESHOOTING POINTS 754
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 755
SEQUENCE OF EVENTS IN TROUBLESHOOTING 767
CHECKS BEFORE TROUBLESHOOTING 769
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 771
WALK-AROUND CHECK 771
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 773
CHECK FUEL LEVEL AND TYPE 773
CHECK IMPURE INGREDIENT IN FUEL 773
CHECK AdBule/DEF LEVEL AND TYPE 774
CHECK FUEL PREFILTER 774
CHECK MAIN FILTER 776
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 777
CHECK COOLANT LEVEL (RESERVOIR TANK) 778
CHECK CLOGGING OF AIR CLEANER 779
CLEAN OUTER ELEMENT 779
REPLACE ELEMENT 782
CHECK HYDRAULIC OIL LEVEL 782
CHECK HYDRAULIC OIL STRAINER 783
CHECK HYDRAULIC FILTER 786
CHECK OIL LEVEL IN FINAL DRIVE CASE 787
BLEED AIR FROM FUEL SYSTEM 788
BLEED AIR FROM HYDRAULIC SYSTEM 788
METHOD FOR CHECKING ELECTRIC EQUIPMENT 788
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 795
PROCEDURE FOR TROUBLESHOOTING 802
SYMPTOM AND TROUBLESHOOTING NUMBERS 805
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 808
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 810
CONNECTORS LIST AND LAYOUT 813
CONNECTOR CONTACT IDENTIFICATION 827
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 867
FUSE LOCATION TABLE 873
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 877
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 881
FAILURE CODES TABLE 883
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 902
FAILURE CODE [6091NX] 902
FAILURE CODE [989L00] 904
FAILURE CODE [989M00] 905
FAILURE CODE [989N00] 906
FAILURE CODE [A1U0N3] 907
FAILURE CODE [A1U0N4] 909
FAILURE CODE [A900FR] 911
FAILURE CODE [A900N6] 912
FAILURE CODE [A900NY] 913
FAILURE CODE [AA10NX] 914
FAILURE CODE [AB00KE] 916
FAILURE CODE [AQ10N3] 918
FAILURE CODE [AS00N3] 920
FAILURE CODE [AS00R2] 922
FAILURE CODE [AS00R3] 923
FAILURE CODE [AS00R4] 924
FAILURE CODE [AS00R5] 925
FAILURE CODE [AS00R6] 926
FAILURE CODE [AS00ZK] 927
FAILURE CODE [AS10KM] 928
FAILURE CODE [AS10NR] 929
FAILURE CODE [AS10NT] 930
FAILURE CODE [B@BAZG] 931
FAILURE CODE [B@BCNS] 932
FAILURE CODE [B@CRNS] 933
FAILURE CODE [B@CRZG] 934
FAILURE CODE [CA115] 935
FAILURE CODE [CA122] 936
FAILURE CODE [CA123] 938
FAILURE CODE [CA131] 940
FAILURE CODE [CA132] 942
FAILURE CODE [CA144] 944
FAILURE CODE [CA145] 946
FAILURE CODE [CA153] 948
FAILURE CODE [CA154] 951
FAILURE CODE [CA187] 953
FAILURE CODE [CA221] 955
FAILURE CODE [CA222] 957
FAILURE CODE [CA227] 959
FAILURE CODE [CA234] 960
FAILURE CODE [CA238] 961
FAILURE CODE [CA239] 963
FAILURE CODE [CA249] 965
FAILURE CODE [CA256] 967
FAILURE CODE [CA271] 969
FAILURE CODE [CA272] 971
FAILURE CODE [CA322] 973
FAILURE CODE [CA323] 975
FAILURE CODE [CA324] 977
FAILURE CODE [CA325] 979
FAILURE CODE [CA331] 981
FAILURE CODE [CA332] 983
FAILURE CODE [CA343] 985
FAILURE CODE [CA351] 986
FAILURE CODE [CA352] 987
FAILURE CODE [CA356] 990
FAILURE CODE [CA357] 992
FAILURE CODE [CA386] 995
FAILURE CODE [CA428] 996
FAILURE CODE [CA429] 998
FAILURE CODE [CA435] 1000
FAILURE CODE [CA441] 1002
FAILURE CODE [CA442] 1004
FAILURE CODE [CA449] 1005
FAILURE CODE [CA451] 1006
FAILURE CODE [CA452] 1008
FAILURE CODE [CA488] 1010
FAILURE CODE [CA515] 1011
FAILURE CODE [CA516] 1013
FAILURE CODE [CA553] 1015
FAILURE CODE [CA555] 1016
FAILURE CODE [CA556] 1017
FAILURE CODE [CA559] 1018
FAILURE CODE [CA595] 1021
FAILURE CODE [CA687] 1022
FAILURE CODE [CA689] 1024
FAILURE CODE [CA691] 1027
FAILURE CODE [CA692] 1029
FAILURE CODE [CA697] 1031
FAILURE CODE [CA698] 1032
FAILURE CODE [CA731] 1033
FAILURE CODE [CA778] 1035
FAILURE CODE [CA1117] 1040
FAILURE CODE [CA1664] 1041
FAILURE CODE [CA1669] 1044
FAILURE CODE [CA1673] 1045
FAILURE CODE [CA1677] 1046
FAILURE CODE [CA1678] 1047
FAILURE CODE [CA1682] 1048
FAILURE CODE [CA1683] 1052
FAILURE CODE [CA1684] 1054
FAILURE CODE [CA1686] 1056
FAILURE CODE [CA1691] 1057
FAILURE CODE [CA1694] 1060
FAILURE CODE [CA1695] 1063
FAILURE CODE [CA1696] 1064
FAILURE CODE [CA1712] 1066
FAILURE CODE [CA1713] 1069
FAILURE CODE [CA1714] 1071
FAILURE CODE [CA1715] 1072
FAILURE CODE [CA1776] 1073
FAILURE CODE [CA1777] 1076
FAILURE CODE [CA1843] 1079
FAILURE CODE [CA1844] 1081
FAILURE CODE [CA1879] 1084
FAILURE CODE [CA1881] 1087
FAILURE CODE [CA1883] 1089
FAILURE CODE [CA1885] 1093
FAILURE CODE [CA1887] 1095
FAILURE CODE [CA1921] 1097
FAILURE CODE [CA1922] 1100
FAILURE CODE [CA1942] 1105
FAILURE CODE [CA1993] 1106
FAILURE CODE [CA2185] 1109
FAILURE CODE [CA2186] 1111
FAILURE CODE [CA2249] 1113
FAILURE CODE [CA2271] 1114
FAILURE CODE [CA2272] 1117
FAILURE CODE [CA2288] 1120
FAILURE CODE [CA2311] 1121
FAILURE CODE [CA2349] 1122
FAILURE CODE [CA2353] 1125
FAILURE CODE [CA2357] 1127
FAILURE CODE [CA2381] 1128
FAILURE CODE [CA2382] 1131
FAILURE CODE [CA2383] 1134
FAILURE CODE [CA2386] 1137
FAILURE CODE [CA2387] 1139
FAILURE CODE [CA2555] 1140
FAILURE CODE [CA2556] 1143
FAILURE CODE [CA2637] 1146
FAILURE CODE [CA2639] 1148
FAILURE CODE [CA2771] 1151
FAILURE CODE [CA2777] 1157
FAILURE CODE [CA2976] 1160
FAILURE CODE [CA3133] 1162
FAILURE CODE [CA3134] 1164
FAILURE CODE [CA3135] 1166
FAILURE CODE [CA3142] 1170
FAILURE CODE [CA3143] 1171
FAILURE CODE [CA3144] 1172
FAILURE CODE [CA3146] 1174
FAILURE CODE [CA3147] 1175
FAILURE CODE [CA3148] 1176
FAILURE CODE [CA3151] 1178
FAILURE CODE [CA3165] 1184
FAILURE CODE [CA3229] 1186
FAILURE CODE [CA3231] 1188
FAILURE CODE [CA3232] 1190
FAILURE CODE [CA3235] 1194
FAILURE CODE [CA3239] 1196
FAILURE CODE [CA3241] 1199
FAILURE CODE [CA3242] 1202
FAILURE CODE [CA3251] 1205
FAILURE CODE [CA3253] 1207
FAILURE CODE [CA3254] 1210
FAILURE CODE [CA3255] 1213
FAILURE CODE [CA3256] 1216
FAILURE CODE [CA3311] 1218
FAILURE CODE [CA3312] 1220
FAILURE CODE [CA3313] 1223
FAILURE CODE [CA3314] 1224
FAILURE CODE [CA3315] 1225
FAILURE CODE [CA3316] 1228
FAILURE CODE [CA3317] 1229
FAILURE CODE [CA3318] 1230
FAILURE CODE [CA3319] 1233
FAILURE CODE [CA3321] 1234
FAILURE CODE [CA3322] 1236
FAILURE CODE [CA3419] 1239
FAILURE CODE [CA3421] 1241
FAILURE CODE [CA3497] 1243
FAILURE CODE [CA3498] 1244
FAILURE CODE [CA3543] 1245
FAILURE CODE [CA3545] 1252
FAILURE CODE [CA3547] 1254
FAILURE CODE [CA3558] 1255
FAILURE CODE [CA3559] 1257
FAILURE CODE [CA3562] 1259
FAILURE CODE [CA3563] 1261
FAILURE CODE [CA3567] 1264
FAILURE CODE [CA3568] 1267
FAILURE CODE [CA3571] 1273
FAILURE CODE [CA3572] 1275
FAILURE CODE [CA3574] 1277
FAILURE CODE [CA3575] 1280
FAILURE CODE [CA3577] 1282
FAILURE CODE [CA3578] 1284
FAILURE CODE [CA3582] 1286
FAILURE CODE [CA3583] 1294
FAILURE CODE [CA3596] 1296
FAILURE CODE [CA3649] 1299
FAILURE CODE [CA3681] 1301
FAILURE CODE [CA3682] 1306
FAILURE CODE [CA3713] 1312
FAILURE CODE [CA3717] 1315
FAILURE CODE [CA3718] 1316
FAILURE CODE [CA3725] 1317
FAILURE CODE [CA3741] 1320
FAILURE CODE [CA3748] 1321
FAILURE CODE [CA3751] 1323
FAILURE CODE [CA3755] 1325
FAILURE CODE [CA3866] 1327
FAILURE CODE [CA3867] 1331
FAILURE CODE [CA3868] 1334
FAILURE CODE [CA3899] 1338
FAILURE CODE [CA3911] 1340
FAILURE CODE [CA3912] 1344
FAILURE CODE [CA3932] 1346
FAILURE CODE [CA3933] 1348
FAILURE CODE [CA3934] 1350
FAILURE CODE [CA3935] 1353
FAILURE CODE [CA3936] 1355
FAILURE CODE [CA4151] 1357
FAILURE CODE [CA4152] 1361
FAILURE CODE [CA4155] 1365
FAILURE CODE [CA4156] 1367
FAILURE CODE [CA4157] 1370
FAILURE CODE [CA4158] 1372
FAILURE CODE [CA4159] 1373
FAILURE CODE [CA4161] 1374
FAILURE CODE [CA4162] 1377
FAILURE CODE [CA4163] 1380
FAILURE CODE [CA4164] 1382
FAILURE CODE [CA4165] 1384
FAILURE CODE [CA4166] 1386
FAILURE CODE [CA4168] 1388
FAILURE CODE [CA4169] 1391
FAILURE CODE [CA4171] 1393
FAILURE CODE [CA4249] 1396
FAILURE CODE [CA4251] 1398
FAILURE CODE [CA4259] 1400
FAILURE CODE [CA4261] 1403
FAILURE CODE [CA4277] 1406
FAILURE CODE [CA4281] 1410
FAILURE CODE [CA4459] 1413
FAILURE CODE [CA4461] 1416
FAILURE CODE [CA4658] 1419
FAILURE CODE [CA4731] 1423
FAILURE CODE [CA4732] 1424
FAILURE CODE [CA4739] 1425
FAILURE CODE [CA4768] 1426
FAILURE CODE [CA4769] 1428
FAILURE CODE [CA4842] 1431
FAILURE CODE [CA4952] 1435
FAILURE CODE [CA5115] 1437
FAILURE CODE [CA5383] 1440
FAILURE CODE [D130KA] 1442
FAILURE CODE [D130KB] 1445
FAILURE CODE [D130KY] 1447
FAILURE CODE [D19JKZ] 1449
FAILURE CODE [D811MC] 1452
FAILURE CODE [D862KA] 1453
FAILURE CODE [D8ALKA] 1454
FAILURE CODE [D8ALKB] 1456
FAILURE CODE [D8AQKR] 1458
FAILURE CODE [D8G1KT] 1460
FAILURE CODE [D8G6KT] 1461
FAILURE CODE [DAF0MB] 1462
FAILURE CODE [DAF0MC] 1463
FAILURE CODE [DAF8KB] 1464
FAILURE CODE [DAF9KQ] 1466
FAILURE CODE [DAFGMC] 1467
FAILURE CODE [DAFLKA] 1468
FAILURE CODE [DAFLKB] 1470
FAILURE CODE [DAFQKR] 1472
FAILURE CODE [DAJ000] 1473
FAILURE CODE [DAJ0KQ] 1474
FAILURE CODE [DAJ0KT] 1475
FAILURE CODE [DAJ0MC] 1476
FAILURE CODE [DAJ1KK] 1477
FAILURE CODE [DAJ2KK] 1479
FAILURE CODE [DAJ5KK] 1481
FAILURE CODE [DAJ6KK] 1484
FAILURE CODE [DAJLKA] 1486
FAILURE CODE [DAJLKB] 1488
FAILURE CODE [DAJPMA] 1490
FAILURE CODE [DAJQKR] 1491
FAILURE CODE [DAJRKR] 1492
FAILURE CODE [DB2QKR] 1493
FAILURE CODE [DB2RKR] 1498
FAILURE CODE [DD12KA] 1503
FAILURE CODE [DD12KB] 1505
FAILURE CODE [DD13KA] 1507
FAILURE CODE [DD13KB] 1509
FAILURE CODE [DD14KA] 1511
FAILURE CODE [DD14KB] 1513
FAILURE CODE [DDKAKA] 1515
FAILURE CODE [DDKAKB] 1517
FAILURE CODE [DDKFL4] 1519
FAILURE CODE [DDKGL4] 1521
FAILURE CODE [DDKHKA] 1523
FAILURE CODE [DDKHKB] 1525
FAILURE CODE [DDNLKA] 1527
FAILURE CODE [DDNLKB] 1529
FAILURE CODE [DDP6KA] 1531
FAILURE CODE [DDP6KB] 1534
FAILURE CODE [DDP6MA] 1536
FAILURE CODE [DDU1FS] 1538
FAILURE CODE [DDU1KA] 1540
FAILURE CODE [DDU1KY] 1543
FAILURE CODE [DFA4KX] 1545
FAILURE CODE [DFA4KZ] 1546
FAILURE CODE [DFA4L8] 1547
FAILURE CODE [DFA5KA] 1548
FAILURE CODE [DFA5KB] 1551
FAILURE CODE [DFA6KA] 1554
FAILURE CODE [DFA6KB] 1557
FAILURE CODE [DFA7KX] 1560
FAILURE CODE [DFA7KZ] 1561
FAILURE CODE [DFA7L8] 1562
FAILURE CODE [DFA8KA] 1563
FAILURE CODE [DFA8KB] 1566
FAILURE CODE [DFA9KA] 1569
FAILURE CODE [DFA9KB] 1572
FAILURE CODE [DGS1KA] 1575
FAILURE CODE [DGS1KX] 1578
FAILURE CODE [DH21KA] 1579
FAILURE CODE [DH21KB] 1581
FAILURE CODE [DHA4KA] 1583
FAILURE CODE [DHAAMA] 1585
FAILURE CODE [DHACMA] 1587
FAILURE CODE [DHH7KA] 1589
FAILURE CODE [DHH7KB] 1592
FAILURE CODE [DHH8KA] 1594
FAILURE CODE [DHH8KB] 1597
FAILURE CODE [DHH9KA] 1599
FAILURE CODE [DHH9KB] 1602
FAILURE CODE [DHHAKA] 1604
FAILURE CODE [DHHAKB] 1607
FAILURE CODE [DK30KA] 1609
FAILURE CODE [DK30KB] 1612
FAILURE CODE [DK30KX] 1614
FAILURE CODE [DK30KZ] 1615
FAILURE CODE [DK30L8] 1616
FAILURE CODE [DK31KA] 1617
FAILURE CODE [DK31KB] 1620
FAILURE CODE [DK40KA] 1622
FAILURE CODE [DK40KB] 1625
FAILURE CODE [DK55KX] 1627
FAILURE CODE [DK55KZ] 1628
FAILURE CODE [DK55L8] 1629
FAILURE CODE [DK56KA] 1630
FAILURE CODE [DK56KB] 1633
FAILURE CODE [DK57KA] 1635
FAILURE CODE [DK57KB] 1638
FAILURE CODE [DLM0KX] 1640
FAILURE CODE [DLM1KA] 1641
FAILURE CODE [DLM1KB] 1643
FAILURE CODE [DLM1MA] 1645
FAILURE CODE [DLM2KA] 1646
FAILURE CODE [DLM2KB] 1648
FAILURE CODE [DLM2MA] 1650
FAILURE CODE [DLM3KA] 1651
FAILURE CODE [DLM3KB] 1653
FAILURE CODE [DLM3MB] 1655
FAILURE CODE [DN21FS] 1656
FAILURE CODE [DR21KX] 1658
FAILURE CODE [DR31KX] 1659
FAILURE CODE [DV20KB] 1660
FAILURE CODE [DW4BKA] 1662
FAILURE CODE [DW4BKB] 1664
FAILURE CODE [DW4BKY] 1666
FAILURE CODE [DW7BKA] 1668
FAILURE CODE [DW7BKB] 1670
FAILURE CODE [DW7EKA] 1672
FAILURE CODE [DW7EKB] 1674
FAILURE CODE [DW7EKY] 1676
FAILURE CODE [DWN5KA] 1678
FAILURE CODE [DWN5KB] 1680
FAILURE CODE [DWN5KY] 1682
FAILURE CODE [DXA4KA] 1684
FAILURE CODE [DXA4KB] 1686
FAILURE CODE [DXA4KY] 1688
FAILURE CODE [DXA5KA] 1690
FAILURE CODE [DXA5KB] 1692
FAILURE CODE [DXA5KY] 1694
FAILURE CODE [DXA6KA] 1696
FAILURE CODE [DXA6KB] 1698
FAILURE CODE [DXA6KY] 1700
FAILURE CODE [DXA7KA] 1702
FAILURE CODE [DXA7KB] 1704
FAILURE CODE [DXA7KY] 1706
FAILURE CODE [DXHRKA] 1708
FAILURE CODE [DXHRKB] 1710
FAILURE CODE [DXHRKY] 1712
FAILURE CODE [DXHSKA] 1714
FAILURE CODE [DXHSKB] 1716
FAILURE CODE [DXHSKY] 1718
FAILURE CODE [DXHTKA] 1720
FAILURE CODE [DXHTKB] 1722
FAILURE CODE [DXHTKY] 1724
FAILURE CODE [DXHUKA] 1726
FAILURE CODE [DXHUKB] 1728
FAILURE CODE [DXHUKY] 1730
FAILURE CODE [DXJ4KA] 1732
FAILURE CODE [DXJ4KB] 1734
FAILURE CODE [DXJCKA] 1736
FAILURE CODE [DXJCKB] 1738
FAILURE CODE [DXJCKY] 1740
FAILURE CODE [DXJDKA] 1742
FAILURE CODE [DXJDKB] 1744
FAILURE CODE [DXJDKY] 1746
FAILURE CODE [DXK1KA] 1748
FAILURE CODE [DXK1KB] 1750
FAILURE CODE [DXK1KY] 1752
FAILURE CODE [DXK2KA] 1754
FAILURE CODE [DXK2KB] 1756
FAILURE CODE [DXK2KY] 1758
FAILURE CODE [F313KA] 1760
FAILURE CODE [F313KB] 1761
FAILURE CODE [F318KB] 1762
FAILURE CODE [F318KY] 1763
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1764
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1764
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1771
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1774
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1776
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1778
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 1782
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1783
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1784
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1785
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1786
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1787
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1788
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1789
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1790
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1791
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1794
E-17 OPERATION MODE DOES NOT CHANGE 1795
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 1796
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 1797
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1798
E-21 SERVICE MODE CANNOT BE SELECTED 1799
E-22 WORK EQUIPMENT DOES NOT OPERATE 1800
E-23 FOOT HEATER DOES NOT OPERATE 1802
E-24 HORN DOES NOT SOUND 1808
E-25 HORN DOES NOT STOP SOUNDING 1810
E-26 BACKUP ALARM DOES NOT SOUND 1811
E-27 BACKUP ALARM DOES NOT STOP SOUNDING 1812
E-28 HEADLAMP DOES NOT LIGHT UP 1813
E-29 REAR LAMP DOES NOT LIGHT UP 1817
E-30 ALL WIPERS DO NOT OPERATE 1820
E-31 FRONT WIPER DOES NOT OPERATE 1822
E-32 REAR WIPER DOES NOT OPERATE 1824
E-33 LEFT DOOR WIPER DOES NOT OPERATE 1826
E-34 RIGHT DOOR WIPER DOES NOT OPERATE 1830
E-35 FRONT WASHER DOES NOT OPERATE 1834
E-36 REAR WASHER DOES NOT OPERATE 1836
E-37 LEFT DOOR WASHER DOES NOT OPERATE 1838
E-38 RIGHT DOOR WASHER DOES NOT OPERATE 1840
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1842
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1843
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1843
FAILURE MODE AND CAUSE TABLE 1844
H-1 NEITHER R H NOR L H OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) 1850
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) 1852
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) 1854
H-4 TRAVEL SPEED OR POWER IS LOW 1856
H-5 SPEED RANGE DOES NOT CHANGE 1858
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS 1859
H-7 MACHINE DEVIATES LARGELY 1860
H-8 MACHINE DRIFT ON A SLOPE IS LARGE 1863
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1865
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 1867
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 1869
H-12 ALL WORK EQUIPMENT DO NOT OPERATE 1871
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 1873
H-14 BLADE LIFT SPEED OR POWER IS LOW 1874
H-15 BLADE TILT SPEED OR POWER IS LOW 1876
H-16 BLADE ANGLE SPEED OR POWER IS LOW 1877
H-17 TIME LAG OF BLADE LIFT IS LARGE 1878
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 1879
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 1880
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 1881
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1882
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1884
TROUBLESHOOTING OF ENGINE (S-MODE) 1885
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1885
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1886
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1887
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1888
S-4 ENGINE STARTABILITY IS POOR 1890
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1892
S-6 ENGINE STOPS DURING OPERATION 1894
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1896
S-8 ENGINE LACKS POWER 1897
S-9 KDPF GETS CLOGGED IN A SHORT TIME 1899
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1901
S-11 OIL BECOMES CONTAMINATED QUICKLY 1902
S-12 FUEL CONSUMPTION IS EXCESSIVE 1903
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1904
S-14 OIL PRESSURE DROPS 1905
S-15 FUEL MIXES INTO ENGINE OIL 1907
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1908
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1909
S-18 UNUSUAL NOISE IS HEARD 1910
S-19 VIBRATION IS EXCESSIVE 1911
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1912
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1913
S-22 ACTIVE REGENERATION TAKES TIME 1915
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1916
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1917
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1919
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1920
50 DISASSEMBLY AND ASSEMBLY 1921
CONTENTS 1922
ABBREVIATION LIST 1927
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1933
HOW TO READ THIS MANUAL 1933
COATING MATERIALS LIST 1935
SPECIAL TOOLS LIST 1939
SKETCHES OF SPECIAL TOOLS 1958
ENGINE AND COOLING SYSTEM 1971
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1971
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1972
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1977
REMOVE AND INSTALL INJECTOR ASSEMBLY 1984
METHOD FOR REMOVING INJECTOR ASSEMBLY 1984
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1991
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2001
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2001
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2013
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2031
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2031
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2032
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2034
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2034
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2036
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2039
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2039
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2041
REMOVE AND INSTALL ALTERNATOR BELT 2043
METHOD FOR REMOVING ALTERNATOR BELT 2043
METHOD FOR INSTALLING ALTERNATOR BELT 2044
REMOVE AND INSTALL AUTOMATIC TENSIONER 2046
METHOD FOR REMOVING AUTOMATIC TENSIONER 2046
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2046
REMOVE AND INSTALL RADIATOR ASSEMBLY 2047
METHOD FOR REMOVING RADIATOR ASSEMBLY 2047
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2050
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2054
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2054
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2057
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2060
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2060
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2063
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2067
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2067
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2070
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2074
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2074
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2077
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY 2081
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY 2081
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY 2090
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2101
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2101
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2102
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2104
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2104
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2106
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2109
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2109
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2112
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2116
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2116
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2122
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2128
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2128
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2134
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2140
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2140
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2141
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2144
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2144
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2145
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2152
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2152
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2153
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2154
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2154
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2155
REMOVE AND INSTALL KDPF ASSEMBLY 2158
METHOD FOR REMOVING KDPF ASSEMBLY 2159
METHOD FOR INSTALLING KDPF ASSEMBLY 2162
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2165
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2165
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2168
REMOVE AND INSTALL SCR ASSEMBLY 2175
METHOD FOR REMOVING SCR ASSEMBLY 2175
METHOD FOR INSTALLING SCR ASSEMBLY 2177
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2181
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2182
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2188
REMOVE AND INSTALL KCCV ASSEMBLY 2195
METHOD FOR REMOVING KCCV ASSEMBLY 2195
METHOD FOR INSTALLING KCCV ASSEMBLY 2197
REMOVE AND INSTALL VGT ASSEMBLY 2199
METHOD FOR REMOVING VGT ASSEMBLY 2199
METHOD FOR INSTALLING VGT ASSEMBLY 2201
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2204
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2205
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2207
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2211
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2211
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2214
REMOVE AND INSTALL AdBlue/DEF PUMP 2218
METHOD FOR REMOVING AdBlue/DEF PUMP 2218
METHOD FOR INSTALLING AdBlue/DEF PUMP 2221
REMOVE AND INSTALL AdBlue/DEF HOSE 2224
METHOD FOR REMOVING AdBlue/DEF HOSE 2224
METHOD FOR INSTALLING AdBlue/DEF HOSE 2228
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2234
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2234
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2236
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2239
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2239
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2240
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2242
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2242
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2246
POWER TRAIN 2250
REMOVE AND INSTALL DAMPER ASSEMBLY 2250
METHOD FOR REMOVING DAMPER ASSEMBLY 2250
METHOD FOR INSTALLING DAMPER ASSEMBLY 2251
REMOVE AND INSTALL HST PUMP ASSEMBLY 2253
METHOD FOR REMOVING HST PUMP ASSEMBLY 2253
METHOD FOR INSTALLING HST PUMP ASSEMBLY 2255
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY 2257
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY 2257
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY 2260
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2263
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2264
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2269
UNDERCARRIAGE AND FRAME 2278
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2278
METHOD FOR REMOVING TRACK FRAME ASSEMBLY 2278
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY 2282
REMOVE AND INSTALL IDLER ASSEMBLY 2287
METHOD FOR REMOVING IDLER ASSEMBLY 2287
METHOD FOR INSTALLING IDLER ASSEMBLY 2289
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2291
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2291
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2293
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2298
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2298
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2299
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY 2300
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY 2300
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY 2303
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2306
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2306
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2307
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2310
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2310
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2312
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2316
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2316
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2317
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2319
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2319
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2320
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2323
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2323
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2324
SEPARATE AND CONNECT TRACK ASSEMBLY 2326
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY 2326
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2327
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2328
METHOD FOR CONNECTING TRACK ASSEMBLY 2329
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2331
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2331
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2331
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2333
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2333
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2338
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2351
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2352
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2353
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2368
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2369
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2370
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2377
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2378
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2380
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2384
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 2384
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 2386
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS 2389
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS 2389
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS 2389
REMOVE AND INSTALL SEGMENT TEETH 2391
METHOD FOR REMOVING SEGMENT TEETH 2391
METHOD FOR INSTALLING SEGMENT TEETH 2392
HYDRAULIC SYSTEM 2393
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2393
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2394
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2398
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2403
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2403
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2408
WORK EQUIPMENT 2413
REMOVE AND INSTALL BLADE ASSEMBLY 2413
METHOD FOR REMOVING BLADE ASSEMBLY 2413
METHOD FOR INSTALLING BLADE ASSEMBLY 2415
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2418
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2418
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2420
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2422
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2423
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2424
REMOVE AND INSTALL U-FRAME ASSEMBLY 2428
METHOD FOR REMOVING U-FRAME ASSEMBLY 2428
METHOD FOR INSTALLING U-FRAME ASSEMBLY 2430
CAB AND ITS ATTACHMENTS 2432
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2432
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2432
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2439
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2446
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2448
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2448
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2454
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2454
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2460
REMOVE AND INSTALL RECEIVER DRIER 2467
METHOD FOR REMOVING RECEIVER DRIER 2467
METHOD FOR INSTALLING RECEIVER DRIER 2468
REMOVE AND INSTALL OPERATOR’S SEAT 2471
METHOD FOR REMOVING OPERATOR’S SEAT 2471
METHOD FOR INSTALLING OPERATOR’S SEAT 2472
REMOVE AND INSTALL SEAT BELT 2473
METHOD FOR REMOVING SEAT BELT 2473
METHOD FOR INSTALLING SEAT BELT 2473
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 2475
METHOD FOR REMOVING FOOT HEATER ASSEMBLY 2475
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY 2477
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 2480
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY 2480
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY 2481
ELECTRICAL SYSTEM 2482
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2482
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2482
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2484
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 2487
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2487
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2488
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2489
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2489
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2490
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2492
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2492
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2494
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2495
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2495
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2497
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2499
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2499
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2500
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2502
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2502
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2503
REMOVE AND INSTALL COMMUNICATION TERMINAL 2504
REMOVE COMMUNICATION TERMINAL 2504
INSTALL COMMUNICATION TERMINAL 2507
60 MAINTENANCE STANDARD 2511
CONTENTS 2512
ABBREVIATION LIST 2514
ENGINE AND COOLING SYSTEM 2520
MAINTENANCE STANDARD OF ENGINE MOUNT 2520
MAINTENANCE STANDARD OF DAMPER 2521
MAINTENANCE STANDARD OF COOLING SYSTEM 2522
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2524
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2526
POWER TRAIN 2527
MAINTENANCE STANDARD OF HST PUMP 2527
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 2528
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 2529
MAINTENANCE STANDARD OF HST CHARGE PUMP 2530
MAINTENANCE STANDARD OF HST MOTOR 2532
MAINTENANCE STANDARD OF FINAL DRIVE 2533
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 2535
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 2536
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2538
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 2539
UNDERCARRIAGE AND FRAME 2541
MAINTENANCE STANDARD OF SUSPENSION 2541
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2543
MAINTENANCE STANDARD OF IDLER 2545
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2547
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2548
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2549
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2550
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE 2551
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2552
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 2553
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2555
MAINTENANCE STANDARD OF SINGLE SHOE 2557
MAINTENANCE STANDARD OF SWAMP SHOE 2558
HYDRAULIC SYSTEM 2559
MAINTENANCE STANDARD OF HYDRAULIC TANK 2559
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2560
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP 2561
MAINTENANCE STANDARD OF CONTROL VALVE 2563
MAINTENANCE STANDARD OF RIPPER PPC VALVE 2570
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID 2572
MAINTENANCE STANDARD OF EPC VALVE 2573
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE 2574
MAINTENANCE STANDARD OF QUICK DROP VALVE 2575
WORK EQUIPMENT 2577
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 2577
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 2580
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 2581
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 2582
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER 2583
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 2584
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 2586
CAB AND ITS ATTACHMENTS 2587
MAINTENANCE STANDARD OF CAB MOUNT 2587
ELECTRICAL SYSTEM 2588
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 2588
80 APPENDIX 2589
CONTENTS 2590
ABBREVIATION LIST 2591
AIR CONDITIONER SYSTEM 2597
PRECAUTIONS FOR REFRIGERANT 2597
AIR CONDITIONER COMPONENT 2598
SPECIFICATIONS OF AIR CONDITIONER 2601
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2602
OUTLINE OF REFRIGERATION CYCLE 2603
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2605
AIR CONDITIONER UNIT 2605
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2605
FUNCTION OF AIR CONDITIONER UNIT 2606
COMPONENT PARTS OF AIR CONDITIONER UNIT 2607
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2607
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2607
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT 2607
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2608
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2608
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2608
FUNCTION OF DUAL PRESSURE SWITCH 2609
FUNCTION OF PRESSURE SWITCH 2609
COMPRESSOR 2610
STRUCTURE OF COMPRESSOR 2610
SPECIFICATIONS OF COMPRESSOR 2610
FUNCTION OF COMPRESSOR 2610
CONDENSER 2611
STRUCTURE OF CONDENSER 2611
SPECIFICATIONS OF CONDENSER 2611
FUNCTION OF CONDENSER 2612
RECEIVER DRIER 2613
STRUCTURE OF RECEIVER DRIER 2613
SPECIFICATIONS OF RECEIVER DRIER 2613
FUNCTION OF RECEIVER DRIER 2613
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2615
CIRCUIT DIAGRAM OF AIR CONDITIONER 2618
AIR CONDITIONER SYSTEM DIAGRAM 2619
CONTROL FUNCTION OF AIR CONDITIONER 2620
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2621
TEST RELAYS 2625
METHOD FOR TESTING RELAYS 2625
AIR CONDITIONER TROUBLESHOOTING CHART 1 2627
AIR CONDITIONER TROUBLESHOOTING CHART 2 2628
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2631
A-1 TROUBLESHOOTING FOR CONDENSER FAN 2633
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2636
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2640
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 2643
TROUBLESHOOTING USING GAUGE PRESSURE 2647
CONNECTION OF SERVICE TOOL 2649
METHOD FOR CONNECTING SERVICE TOOL 2649
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2650
HANDLE COMPRESSOR OIL 2652
90 CIRCUIT DIAGRAMS 2655
CONTENTS 2656
ABBREVIATION LIST 2657
HYDRAULIC CIRCUIT DIAGRAM 2663
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2663
HYDRAULIC CIRCUIT DIAGRAM 2667
ELECTRICAL CIRCUIT DIAGRAM 2669
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2669
ELECTRICAL CIRCUIT DIAGRAM (1/16) 2673
ELECTRICAL CIRCUIT DIAGRAM (2/16) 2675
ELECTRICAL CIRCUIT DIAGRAM (3/16) 2677
ELECTRICAL CIRCUIT DIAGRAM (4/16) 2679
ELECTRICAL CIRCUIT DIAGRAM (5/16) 2681
ELECTRICAL CIRCUIT DIAGRAM (6/16) 2683
ELECTRICAL CIRCUIT DIAGRAM (7/16) 2685
ELECTRICAL CIRCUIT DIAGRAM (8/16) 2687
ELECTRICAL CIRCUIT DIAGRAM (9/16) 2689
ELECTRICAL CIRCUIT DIAGRAM (10/16) 2691
ELECTRICAL CIRCUIT DIAGRAM (11/16) 2693
ELECTRICAL CIRCUIT DIAGRAM (12/16) 2695
ELECTRICAL CIRCUIT DIAGRAM (13/16) 2697
ELECTRICAL CIRCUIT DIAGRAM (14/16) 2699
ELECTRICAL CIRCUIT DIAGRAM (15/16) 2701
ELECTRICAL CIRCUIT DIAGRAM (16/16) 2703
INDEX 2705

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S.V 27/12/24