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KOMATSU D61EXi-23 D61PXi-23 BULLDOZER SERVICE REPAIR MANUAL(SN30324 & Up) – PDF Download
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- KOMATSU D61EXi-23 D61PXi-23 BULLDOZER SERVICE REPAIR MANUAL
- Serial Number:30324 & Up
- Publication Number:SEN06256-01
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Description
KOMATSU D61EXi-23 D61PXi-23 BULLDOZER SERVICE REPAIR MANUAL(SN30324 & Up)
KOMATSU D61EXI-23 D61PXI-23 BULLDOZER SERVICE REPAIR MANUAL(SN30324 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D61EXi-23 D61PXi-23 BULLDOZER SERVICE REPAIR MANUAL(SN30324 & Up)
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams
TABLE OF CONTENTS:
KOMATSU D61EXi-23 D61PXi-23 BULLDOZER SERVICE REPAIR MANUAL(SN30324 & Up)
Cover....................................................................................................................................................... 1 00 Index and foreword ...................................................................................................................................... 3 Index .................................................................................................................................................. 4 Foreword, safety and general information ............................................................................................................... 18 Important safety notice ............................................................................................................................ 18 How to read the shop manual ........................................................................................................................ 25 Explanation of terms for maintenance standard ...................................................................................................... 27 Handling equipment of fuel system devices .......................................................................................................... 29 Handling of intake system parts .................................................................................................................... 30 Handling of hydraulic equipment .................................................................................................................... 31 Method of disconnecting and connecting of push-pull type coupler ................................................................................... 33 Handling of electrical equipment ................................................................................................................... 36 How to read electric wire code ..................................................................................................................... 44 Precautions when performing operation .............................................................................................................. 47 Practical use of KOMTRAX ........................................................................................................................... 52 Standard tightening torque table ................................................................................................................... 53 List of abbreviation ............................................................................................................................... 59 Conversion table ................................................................................................................................... 64 01 Specification ........................................................................................................................................... 69 Table of contents ...................................................................................................................................... 70 Specifications ......................................................................................................................................... 71 Specification drawing .............................................................................................................................. 71 Specifications ..................................................................................................................................... 73 Weight table ....................................................................................................................................... 83 Table of fuel, coolant, and lubricants ............................................................................................................. 87 10 Structure and function .................................................................................................................................. 89 Table of contents ...................................................................................................................................... 90 Engine and cooling system .............................................................................................................................. 91 Engine related parts ............................................................................................................................... 91 KVGT ............................................................................................................................................... 93 EGR system piping drawing .......................................................................................................................... 101 EGR system circuit diagram ......................................................................................................................... 103 EGR valve .......................................................................................................................................... 105 EGR cooler ......................................................................................................................................... 107 KCCV layout drawing ................................................................................................................................ 109 KCCV ventilator .................................................................................................................................... 111 KDPF ............................................................................................................................................... 113 Cooling system ..................................................................................................................................... 119 Cooling fan motor .................................................................................................................................. 121 Oil cooler bypass and HST charge safety valve ...................................................................................................... 128 Power train ............................................................................................................................................ 134 Power train system ................................................................................................................................. 134 Damper ............................................................................................................................................. 137 Hydraulic component layout of HST .................................................................................................................. 138 Steering and brake control ......................................................................................................................... 139 HST pump ........................................................................................................................................... 141 HST motor .......................................................................................................................................... 155 Charge pump ........................................................................................................................................ 170 Solenoid valve ..................................................................................................................................... 171 Final drive ........................................................................................................................................ 180 Undercarriage and frame ................................................................................................................................ 184 Main frame ......................................................................................................................................... 184 Suspension ......................................................................................................................................... 185 Track frame and idler cushion ...................................................................................................................... 187 Hydraulic system ....................................................................................................................................... 190 Hydraulic component layout of work equipment ....................................................................................................... 190 Work equipment control system ...................................................................................................................... 192 Hydraulic tank ..................................................................................................................................... 194 CLSS ............................................................................................................................................... 196 Work equipment and cooling fan pump ................................................................................................................ 199 Control valve ...................................................................................................................................... 210 Ripper PPC valve ................................................................................................................................... 232 Quick drop valve ................................................................................................................................... 238 Angle control EPC valve ............................................................................................................................ 241 Accumulator ........................................................................................................................................ 246 Work equipment ......................................................................................................................................... 248 Blade .............................................................................................................................................. 248 Ripper ............................................................................................................................................. 249 Piston valve ....................................................................................................................................... 250 Cab and its attachments ................................................................................................................................ 251 ROPS cab ........................................................................................................................................... 251 Cab mount .......................................................................................................................................... 253 Electrical system ...................................................................................................................................... 254 Electrical control system .......................................................................................................................... 254 Machine monitor system ............................................................................................................................. 296 KOMTRAX system ..................................................................................................................................... 319 System component parts ............................................................................................................................. 323 Sensor ............................................................................................................................................. 349 20 Standard value tables ................................................................................................................................... 379 Table of contents ...................................................................................................................................... 380 Standard service value table ........................................................................................................................... 381 Standard value table for engine .................................................................................................................... 381 Standard value table for machine ................................................................................................................... 383 Standard value table for electrical system ......................................................................................................... 392 30 Testing and adjusting ................................................................................................................................... 401 Table of contents ...................................................................................................................................... 402 Related information on testing and adjusting ........................................................................................................... 404 Tools for testing and adjusting .................................................................................................................... 404 Sketch of tools for testing and adjusting .......................................................................................................... 407 Engine and cooling system .............................................................................................................................. 409 Testing engine speed ............................................................................................................................... 409 Testing boost pressure ............................................................................................................................. 411 Testing exhaust gas color .......................................................................................................................... 413 Testing and adjusting valve clearance .............................................................................................................. 415 Testing compression pressure ....................................................................................................................... 418 Testing blowby pressure ............................................................................................................................ 422 Testing engine oil pressure ........................................................................................................................ 424 Testing EGR valve and KVGT oil pressures ........................................................................................................... 425 Testing fuel pressure .............................................................................................................................. 426 Testing fuel discharge, return and leakage ......................................................................................................... 431 Bleeding air from fuel system ...................................................................................................................... 436 Testing fuel circuit for leakage ................................................................................................................... 438 Handling cylinder cutout mode operation ............................................................................................................ 439 Handling no-injection cranking operation ........................................................................................................... 440 Testing of KDPF and muffler stack for looseness and damage ......................................................................................... 441 Testing of installed condition of cylinder heads and manifolds ..................................................................................... 442 Testing engine piping for damage and looseness ..................................................................................................... 443 Replacing alternator belt .......................................................................................................................... 444 Power train ............................................................................................................................................ 445 Testing and adjusting HST oil pressure ............................................................................................................. 445 Testing output pressure of solenoid valve .......................................................................................................... 450 Testing if machine travels straight ................................................................................................................ 454 Simple test procedure for brake performance ........................................................................................................ 455 Adjusting deceleration/brake pedal ................................................................................................................. 456 Adjusting parking brake lever ...................................................................................................................... 459 Move disabled machine urgently ..................................................................................................................... 461 Undercarriage and frame ................................................................................................................................ 464 Adjusting idler clearance .......................................................................................................................... 464 Checking sprocket wear ............................................................................................................................. 465 Testing and adjusting track tension ................................................................................................................ 466 Hydraulic system ....................................................................................................................................... 467 Releasing remaining pressure in work equipment cylinder ............................................................................................ 467 Testing and adjusting work equipment oil pressure .................................................................................................. 468 Testing source pressure of control circuit ......................................................................................................... 470 Testing output pressure of work equipment EPC valve and fan EPC valve .............................................................................. 471 Isolating the parts causing hydraulic drift in blade and ripper .................................................................................... 473 Testing internal oil leakage of work equipment cylinder ............................................................................................ 474 Testing fan speed .................................................................................................................................. 476 Testing fan circuit oil pressure ................................................................................................................... 477 Bleeding air from hydraulic circuit ................................................................................................................ 478 Work equipment ......................................................................................................................................... 479 Adjusting work equipment lock lever ................................................................................................................ 479 Adjusting play of blade center ball ................................................................................................................ 481 Electrical system ...................................................................................................................................... 482 Special functions of machine monitor ............................................................................................................... 482 Special functions of iB monitor .................................................................................................................... 566 Testing stroke sensor for lift cylinder ............................................................................................................ 595 Testing stroke sensor for tilt cylinder ............................................................................................................ 597 Testing stroke sensor for angle cylinder ........................................................................................................... 598 Testing and adjusting reset sensor for lift cylinder ............................................................................................... 599 Testing and adjusting reset sensor for angle cylinder .............................................................................................. 600 Adjustment method when HST controller has been replaced ............................................................................................ 601 Adjustment method when ICT sensor controller has been replaced ..................................................................................... 604 Adjustment method when devices have been repaired or replaced ...................................................................................... 607 Adjusting rearview camera angle .................................................................................................................... 609 Handling voltage circuit of engine controller ...................................................................................................... 610 Handling battery disconnect switch ................................................................................................................. 611 Testing diodes ..................................................................................................................................... 612 Pm clinic .............................................................................................................................................. 613 Pm Clinic service .................................................................................................................................. 613 Pm Clinic check sheet .............................................................................................................................. 615 40 Troubleshooting ......................................................................................................................................... 621 Table of contents ...................................................................................................................................... 622 Related information on troubleshooting ................................................................................................................. 631 Troubleshooting points ............................................................................................................................. 631 Sequence of events in troubleshooting .............................................................................................................. 633 Checks before troubleshooting ...................................................................................................................... 635 Inspection procedure before troubleshooting ........................................................................................................ 637 Preparation for troubleshooting of electrical system ............................................................................................... 654 Classification and procedures for troubleshooting .................................................................................................. 658 Symptom and troubleshooting numbers ................................................................................................................ 660 Information in troubleshooting table ............................................................................................................... 663 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ............................................................ 665 Connector list and layout .......................................................................................................................... 668 Connector contact identification ................................................................................................................... 682 T-branch box and T-branch adapter table ............................................................................................................ 720 Fuse location table ................................................................................................................................ 725 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...................................................................................... 730 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .................................................................... 733 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ........................................................ 734 Failure codes table ................................................................................................................................ 735 Troubleshooting by failure code (Display of code) ...................................................................................................... 747 Failure code [6091NX] HST Oil Filter Clogging ...................................................................................................... 747 Failure code [989L00] Engine Controller Lock Caution 1 ............................................................................................. 749 Failure code [989M00] Engine Controller Lock Caution 2 ............................................................................................. 750 Failure code [989N00] Engine Controller Lock Caution 3 ............................................................................................. 751 Failure code [A1U0N3] HC Desorb Request 1 .......................................................................................................... 752 Failure code [A1U0N4] HC Desorb Request 2 .......................................................................................................... 754 Failure code [AA10NX] Air Cleaner Clogging ......................................................................................................... 756 Failure code [AB00KE] Charge Voltage Low ........................................................................................................... 758 Failure code [B@BAZG] Eng Oil Press Low ............................................................................................................ 760 Failure code [B@BCNS] Eng Water Overheat ........................................................................................................... 761 Failure code [B@CRNS] HST Oil Overheat ............................................................................................................. 762 Failure code [B@CRZG] HST Charge Press Low ......................................................................................................... 763 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .............................................................................................. 764 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................................... 765 Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................................ 767 Failure code [CA131] Throttle Sensor High Error .................................................................................................... 769 Failure code [CA132] Throttle Sensor Low Error ..................................................................................................... 771 Failure code [CA144] Coolant Temp Sens High Error .................................................................................................. 773 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................................... 775 Failure code [CA153] Chg Air Temp Sensor High Error ................................................................................................ 777 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................................. 779 Failure code [CA187] Sensor 2 Supply Volt Low Error ................................................................................................ 781 Failure code [CA234] Eng Overspeed ................................................................................................................. 783 Failure code [CA221] Ambient Press Sensor High Error ............................................................................................... 784 Failure code [CA222] Ambient Press Sensor Low Error ................................................................................................ 786 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................................... 788 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................................. 789 Failure code [CA239] Ne Speed Sens Supply Volt High Error .......................................................................................... 790 Failure code [CA271] IMV/PCV1 Short Error .......................................................................................................... 791 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................................... 793 Failure code [CA295] Ambient Pressure Sensor In Range Error ........................................................................................ 795 Failure code [CA322] Inj #1(L#1) Open/Short Error .................................................................................................. 796 Failure code [CA323] Inj #5(L#5) Open/Short Error .................................................................................................. 798 Failure code [CA324] Inj #3(L#3) Open/Short Error .................................................................................................. 800 Failure code [CA325] Inj #6(L#6) Open/Short Error .................................................................................................. 802 Failure code [CA331] Inj #2(L#2) Open/Short Error .................................................................................................. 804 Failure code [CA332] Inj #4(L#4) Open/Short Error .................................................................................................. 806 Failure code [CA343] ECM Critical Internal Failure ................................................................................................. 808 Failure code [CA351] Injectors Drive Circuit Error ................................................................................................. 809 Failure code [CA352] Sensor 1 Supply Volt Low Error ................................................................................................ 810 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................................... 812 Failure code [CA357] Mass Air Flow Sensor Low Error ................................................................................................ 814 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................................... 816 Failure code [CA428] Water in Fuel Sensor High Error ............................................................................................... 817 Failure code [CA429] Water in Fuel Sensor Low Error ................................................................................................ 819 Failure code [CA435] Eng Oil Press Sw Error ........................................................................................................ 821 Failure code [CA441] Battery Voltage Low Error ..................................................................................................... 822 Failure code [CA442] Battery Voltage High Error .................................................................................................... 824 Failure code [CA449] Rail Press Very High Error .................................................................................................... 825 Failure code [CA451] Rail Press Sensor High Error .................................................................................................. 826 Failure code [CA452] Rail Press Sensor Low Error ................................................................................................... 828 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................................... 830 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................................... 831 Failure code [CA516] Rail Press Sens Sup Volt Low Error ............................................................................................ 833 Failure code [CA553] Rail Press High Error ......................................................................................................... 835 Failure code [CA555] Crankcase Press High Error 2 .................................................................................................. 836 Failure code [CA556] Crankcase Press High Error 2 .................................................................................................. 837 Failure code [CA559] Rail Press Low Error .......................................................................................................... 838 Failure code [CA595] Turbo Speed High Error 2 ...................................................................................................... 840 Failure code [CA687] Turbo Speed Low Error ......................................................................................................... 841 Failure code [CA689] Eng Ne Speed Sensor Error ..................................................................................................... 843 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................................... 845 Failure code [CA692] Intake Air Temp Sens Low Error ................................................................................................ 847 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................................... 849 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................................. 850 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................................... 851 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................................... 853 Failure code [CA1117] Persistent Data Lost Error ................................................................................................... 858 Failure code [CA1664] KDOC Malfunction ............................................................................................................. 859 Failure code [CA1691] Regeneration Ineffective ..................................................................................................... 862 Failure code [CA1695] Sens 5 Supply Volt High Error ................................................................................................ 865 Failure code [CA1696] Sens 5 Supply Volt Low Error ................................................................................................. 866 Failure code [CA1843] Crankcase Press Sens High Error .............................................................................................. 868 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................................................... 870 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................................................... 872 Failure code [CA1881] KDPF Delta P Sensor Low Error ................................................................................................ 874 Failure code [CA1883] KDPF Delta P Sens In Range Error ............................................................................................. 876 Failure code [CA1921] KDPF Soot Load High Error 1 .................................................................................................. 880 Failure code [CA1922] KDPF Soot Load High Error 2 .................................................................................................. 883 Failure code [CA1942] Crankcase Press Sens In Range Error .......................................................................................... 888 Failure code [CA1993] KDPF Delta Pressure Low Error ................................................................................................ 889 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................................. 892 Failure code [CA2186] Throt Sensor Sup Volt Low Error .............................................................................................. 893 Failure code [CA2249] Rail Press Very Low Error .................................................................................................... 894 Failure code [CA2271] EGR Valve Pos Sens High Error ................................................................................................ 895 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................................. 897 Failure code [CA2288] Turbo Speed High Error 1 ..................................................................................................... 900 Failure code [CA2311] IMV Solenoid Error ........................................................................................................... 901 Failure code [CA2349] EGR Valve Solenoid Open Error ................................................................................................ 902 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................................... 904 Failure code [CA2357] EGR Valve Servo Error ........................................................................................................ 906 Failure code [CA2373] Exhaust Manifold Press Sens High error ....................................................................................... 907 Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................................................................ 909 Failure code [CA2375] EGR Orifice Temp Sens High Error ............................................................................................. 911 Failure code [CA2376] EGR Orifice Temp Sens Low Error .............................................................................................. 913 Failure code [CA2381] KVGT Pos Sens High Error ..................................................................................................... 915 Failure code [CA2382] KVGT Pos Sens Low Error ...................................................................................................... 917 Failure code [CA2383] KVGT Solenoid Open Error ..................................................................................................... 920 Failure code [CA2386] KVGT Solenoid Short Error .................................................................................................... 922 Failure code [CA2387] KVGT Servo Error ............................................................................................................. 924 Failure code [CA2554] Exh Manifold Press Sens In Range Error ....................................................................................... 925 Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................................ 926 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................................... 928 Failure code [CA2637] KDOC Face Plugging ........................................................................................................... 930 Failure code [CA2639] Manual Stationary Regeneration Request ....................................................................................... 932 Failure code [CA2961] EGR Orifice Temp High Error 1 ................................................................................................ 935 Failure code [CA2973] Chg Air Press Sensor In Range Error .......................................................................................... 936 Failure code [CA3133] KDPF Outlet Press Sens High Error ............................................................................................ 937 Failure code [CA3134] KDPF Outlet Press Sens Low Error ............................................................................................. 939 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ........................................................................................ 941 Failure code [CA3251] KDOC Inlet Temp High Error ................................................................................................... 945 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................................... 948 Failure code [CA3254] KDOC Outlet Temp High Error 1 ................................................................................................ 951 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................................... 954 Failure code [CA3256] KDPF Outlet Temp High Error 1 ................................................................................................ 958 Failure code [CA3311] KDOC Outlet Temp High Error 2 ................................................................................................ 961 Failure code [CA3312] KDPF Outlet Temp High Error 2 ................................................................................................ 964 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ............................................................................................. 967 Failure code [CA3314] KDOC Inlet Temp Sens High Error .............................................................................................. 970 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .......................................................................................... 974 Failure code [CA3316] KDOC Outlet Temp Sens Low Error .............................................................................................. 978 Failure code [CA3317] KDOC Outlet Temp Sens High Error ............................................................................................. 981 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ......................................................................................... 985 Failure code [CA3319] KDPF Outlet Temp Sens High Error ............................................................................................. 989 Failure code [CA3321] KDPF Outlet Temp Sens Low Error .............................................................................................. 993 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ......................................................................................... 996 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .....................................................................................1000 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................................................................1002 Failure code [CA3741] Rail Press Valve Trip Error ..................................................................................................1004 Failure code [D130KA] Neutral relay Open ...........................................................................................................1005 Failure code [D130KB] Neutral relay Short circuit ..................................................................................................1007 Failure code [D130KY] Neutral relay: Hot Short .....................................................................................................1009 Failure code [D19JKZ] Personal Code Relay Abnormality ..............................................................................................1011 Failure code [D811MC] KOMTRAX Error ................................................................................................................1014 Failure code [D862KA] GPS Antenna Open Circuit .....................................................................................................1015 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ........................................................................................1016 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .......................................................................................1018 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ........................................................................................................1019 Failure code [DAF0MB] Monitor ROM Abnormality ......................................................................................................1020 Failure code [DAF0MC] Monitor Error ................................................................................................................1021 Failure code [DAF8KB] Camera Power Supply Short Circuit ............................................................................................1022 Failure code [DAF9KQ] Model Selection Abnormality ..................................................................................................1023 Failure code [DAFGMC] GPS Module Error .............................................................................................................1024 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................................................................1025 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) .......................................................................................1027 Failure code [DAFQKR] CAN2 Discon (Monitor) ........................................................................................................1028 Failure code [DAJ000] HST controller: Abnormality in controller ....................................................................................1029 Failure code [DAJ0KQ] HST controller: Type select signal ...........................................................................................1030 Failure code [DAJ0KT] HST controller: Abnormality in controller ....................................................................................1031 Failure code [DAJ0MC] HST Con Error ................................................................................................................1032 Failure code [DAJ1KK] HST controller: Source voltage low ...........................................................................................1033 Failure code [DAJ2KK] HST controller: Output voltage low ...........................................................................................1035 Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range ..................................................................................1037 Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range ..................................................................................1039 Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) ........................................................................................1041 Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) .......................................................................................1043 Failure code [DAJPMA] Inconsistency of Option Selection (HST) ......................................................................................1044 Failure code [DAJQKR] CAN2 Discon ( HST Con) .......................................................................................................1045 Failure code [DAJRKR] CAN1 Discon ( HST Con) .......................................................................................................1046 Failure code [DB2QKR] CAN2 Discon (Engine Con) .....................................................................................................1047 Failure code [DB2RKR] CAN1 Discon (Engine Con) .....................................................................................................1052 Failure code [DBR0KT] ICT Controller: Abnormality in controller ....................................................................................1057 Failure code [DBR0MC] ICT Con Error ................................................................................................................1058 Failure code [DBR1KK] ICT controller: Source voltage low ...........................................................................................1059 Failure code [DBR2KK] ICT controller: Output voltage low ...........................................................................................1061 Failure code [DBR5KK] ICT: Sensor volt 5V (0) Out of normal range ..................................................................................1063 Failure code [DBRLKA] Operating Lamp Open Circuit (ICT Con) ........................................................................................1065 Failure code [DBRLKB] Operating Lamp Short Circuit (ICT Con) .......................................................................................1067 Failure code [DBRPMA] Inconsistency of Option Selection (ICT) ......................................................................................1068 Failure code [DBRQKR] CAN2 Discon (ICT Con) ........................................................................................................1069 Failure code [DBRRKR] CAN1 Discon (ICT Con) ........................................................................................................1070 Failure code [DBTSKR] LAN Discon (iB Monitor) ......................................................................................................1071 Failure code [DBUTKA] GNSS Antenna Open Circuit ....................................................................................................1073 Failure code [DD12KA] Shift up SW: Open ............................................................................................................1074 Failure code [DD12KB] Shift up SW: Short Circuit ...................................................................................................1076 Failure code [DD13KA] Shift down SW: Open ..........................................................................................................1078 Failure code [DD13KB] Shift down SW: Short Circuit .................................................................................................1080 Failure code [DD14KA] Parking lever SW: Open .......................................................................................................1082 Failure code [DD14KB] Parking lever SW: Short circuit ..............................................................................................1084 Failure code [DDKAKA] Blade float Sw: Open .........................................................................................................1086 Failure code [DDKAKB] Blade float Sw: Short circuit ................................................................................................1088 Failure code [DDKFL4] Left Angle Sw: Signal mismatch ...............................................................................................1090 Failure code [DDKGL4] Right Angle Sw: Signal mismatch ..............................................................................................1092 Failure code [DDKHKA] iB Sw: Open ..................................................................................................................1094 Failure code [DDKHKB] iB Sw: Short circuit .........................................................................................................1096 Failure code [DDNLKA] Weq lock Sw: Open ............................................................................................................1098 Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................................1100 Failure code [DDP6KA] Brake Pressure Sensor: Open ..................................................................................................1102 Failure code [DDP6KB] Brake Pressure Sensor: Hot Short .............................................................................................1104 Failure code [DDP6MA] Brake pressure sensor: Malfunction ...........................................................................................1106 Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch ......................................................................................1108 Failure code [DDU1KA] Parking lever Sw2: Open ......................................................................................................1110 Failure code [DDU1KY] Parking lever Sw2: Hot Short .................................................................................................1112 Failure code [DFA4KX] Blade lift lever: Main and Sub Error .........................................................................................1114 Failure code [DFA4KZ] Blade lift lever: Main and Sub Error .........................................................................................1115 Failure code [DFA4L8] Blade lift lever: Signal mismatch ............................................................................................1116 Failure code [DFA5KA] Blade lift lever1: Open ......................................................................................................1117 Failure code [DFA5KB] Blade lift lever1: Hot Short .................................................................................................1120 Failure code [DFA6KA] Blade lift lever2: Open ......................................................................................................1122 Failure code [DFA6KB] Blade lift lever2: Hot Short .................................................................................................1124 Failure code [DFA7KX] Blade tilt lever: Main and Sub Error .........................................................................................1126 Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error .........................................................................................1127 Failure code [DFA7L8] Blade tilt lever: Signal mismatch ............................................................................................1128 Failure code [DFA8KA] Blade tilt lever1: Open ......................................................................................................1129 Failure code [DFA8KB] Blade tilt lever1: Hot Short .................................................................................................1132 Failure code [DFA9KA] Blade tilt lever2: Open ......................................................................................................1134 Failure code [DFA9KB] Blade tilt lever2: Hot Short .................................................................................................1137 Failure code [DGS1KA] HST oil temp sensor: Open ....................................................................................................1139 Failure code [DGS1KX] HST oil temp sensor: Out of normal range .....................................................................................1141 Failure code [DH21KA] Weq pressure sensor: Open ....................................................................................................1142 Failure code [DH21KB] Weq pressure sensor: Hot Short ...............................................................................................1144 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .........................................................................................1146 Failure code [DHH7KA] LF HST Pressure Sensor: Open .................................................................................................1148 Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short ............................................................................................1150 Failure code [DHH8KA] RF HST Pressure Sensor: Open .................................................................................................1152 Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short ............................................................................................1154 Failure code [DHH9KA] LR HST Pressure Sensor: Open .................................................................................................1156 Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short ............................................................................................1158 Failure code [DHHAKA] RR HST Pressure Sensor: Open .................................................................................................1160 Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short ............................................................................................1162 Failure code [DK30KA] ST lever1: Open ..............................................................................................................1164 Failure code [DK30KB] ST lever1: Hot Short .........................................................................................................1166 Failure code [DK30KX] ST lever: Main and Sub Error .................................................................................................1168 Failure code [DK30KZ] ST lever: Main and Sub Error .................................................................................................1169 Failure code [DK30L8] ST lever: Signal mismatch ....................................................................................................1170 Failure code [DK31KA] ST lever2: Open ..............................................................................................................1171 Failure code [DK31KB] ST lever2: Hot Short .........................................................................................................1173 Failure code [DK40KA] Decel/Brake potentiometer: Open ..............................................................................................1175 Failure code [DK40KB] Decel/Brake potentiometer: Hot Short .........................................................................................1178 Failure code [DK55KX] FR lever: Main and Sub Error .................................................................................................1180 Failure code [DK55KZ] FR lever: Main and Sub Error .................................................................................................1181 Failure code [DK55L8] FR lever: Signal mismatch ....................................................................................................1182 Failure code [DK56KA] FR lever1: Open ..............................................................................................................1183 Failure code [DK56KB] FR lever1: Hot Short .........................................................................................................1185 Failure code [DK57KA] FR lever2: Open ..............................................................................................................1187 Failure code [DK57KB] FR lever2: Hot Short .........................................................................................................1189 Failure code [DK80KA] IMU Sensor: Open .............................................................................................................1191 Failure code [DKS0L8] Blade lift Stroke sensor: Signal mismatch ....................................................................................1193 Failure code [DKS1KA] Blade lift Stroke sensor A: Open .............................................................................................1194 Failure code [DKS1KB] Blade lift Stroke sensor A: Hot Short ........................................................................................1196 Failure code [DKS2KA] Blade lift Stroke sensor B: Open .............................................................................................1198 Failure code [DKS2KB] Blade lift Stroke sensor B: Hot Short ........................................................................................1200 Failure code [DKS3KA] Blade lift Reset sensor: Open ................................................................................................1202 Failure code [DKS3KB] Blade lift Reset sensor: Hot Short ...........................................................................................1204 Failure code [DKS3MB] Blade lift Reset sensor: Signal mismatch .....................................................................................1206 Failure code [DKS4L8] Blade tilt Stroke sensor: Signal mismatch ....................................................................................1207 Failure code [DKS5KA] Blade tilt Stroke sensor A: Open .............................................................................................1208 Failure code [DKS5KB] Blade tilt Stroke sensor A: Hot Short ........................................................................................1210 Failure code [DKS6KA] Blade tilt Stroke sensor B: Open .............................................................................................1212 Failure code [DKS6KB] Blade tilt Stroke sensor B: Hot Short ........................................................................................1214 Failure code [DKS7MB] Blade tilt Reset sensor: Signal mismatch .....................................................................................1216 Failure code [DKSCL8] Angle left Stroke sensor: Signal mismatch ....................................................................................1217 Failure code [DKSDKA] Angle left Stroke sensor A: Open .............................................................................................1218 Failure code [DKSDKB] Angle left Stroke sensor A: Hot Short ........................................................................................1220 Failure code [DKSEKA] Angle left Stroke sensor B: Open .............................................................................................1222 Failure code [DKSEKB] Angle left Stroke sensor B: Hot Short ........................................................................................1224 Failure code [DKSFKA] Angle left Reset sensor: Open ................................................................................................1226 Failure code [DKSFKB] Angle left Reset sensor: Hot Short ...........................................................................................1228 Failure code [DKSFMB] Angle left Reset sensor: Signal mismatch .....................................................................................1230 Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error .....................................................................................1231 Failure code [DLM0MA] HST motor speed sensor: Malfunction ..........................................................................................1232 Failure code [DLM1KA] Left HST motor speed sensor: Open ............................................................................................1233 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit ...................................................................................1235 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction .....................................................................................1237 Failure code [DLM2KA] Right HST motor speed sensor: Open ...........................................................................................1238 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit ..................................................................................1240 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction ....................................................................................1242 Failure code [DLM3KA] Fan rev. sensor: Open ........................................................................................................1243 Failure code [DLM3KB] Fan rev. sensor: Short circuit ...............................................................................................1245 Failure code [DLM3MB] Fan control: Mismatch ........................................................................................................1247 Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch ........................................................................................1248 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ......................................................................................1250 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ......................................................................................1251 Failure code [DV20KB] Back-up alarm: Short circuit .................................................................................................1252 Failure code [DW4BKA] Parking brake solenoid: Open .................................................................................................1254 Failure code [DW4BKB] Parking brake solenoid: Short circuit ........................................................................................1256 Failure code [DW4BKY] Parking brake solenoid: Hot Short ............................................................................................1258 Failure code [DW7BKA] Fan reverse solenoid: Open ...................................................................................................1260 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ..........................................................................................1262 Failure code [DW7EKA] Slow brake solenoid: Open ....................................................................................................1263 Failure code [DW7EKB] Slow brake solenoid: Short circuit ...........................................................................................1265 Failure code [DW7EKY] Slow brake solenoid: Hot Short ...............................................................................................1267 Failure code [DWN5KA] Fan EPC: Open ................................................................................................................1269 Failure code [DWN5KB] Fan EPC: Short circuit .......................................................................................................1271 Failure code [DWN5KY] Fan EPC: Hot Short ...........................................................................................................1272 Failure code [DXA4KA] LF HST pump EPC: Open ........................................................................................................1274 Failure code [DXA4KB] LF HST pump EPC: Short circuit ...............................................................................................1276 Failure code [DXA4KY] LF HST pump EPC: Hot Short ...................................................................................................1277 Failure code [DXA5KA] LR HST pump EPC: Open ........................................................................................................1279 Failure code [DXA5KB] LR HST pump EPC: Short circuit ...............................................................................................1281 Failure code [DXA5KY] LR HST pump EPC: Hot Short ...................................................................................................1283 Failure code [DXA6KA] RF HST pump EPC: Open ........................................................................................................1285 Failure code [DXA6KB] RF HST pump EPC: Short circuit ...............................................................................................1287 Failure code [DXA6KY] RF HST pump EPC: Hot Short ...................................................................................................1288 Failure code [DXA7KA] RR HST pump EPC: Open ........................................................................................................1290 Failure code [DXA7KB] RR HST pump EPC: Short circuit ...............................................................................................1292 Failure code [DXA7KY] RR HST pump EPC: Hot Short ...................................................................................................1293 Failure code [DXHRKA] Blade lift up EPC: Open ......................................................................................................1295 Failure code [DXHRKB] Blade lift up EPC: Short circuit .............................................................................................1297 Failure code [DXHRKY] Blade lift up EPC: Hot short .................................................................................................1298 Failure code [DXHSKA] Blade lift down EPC: Open ....................................................................................................1300 Failure code [DXHSKB] Blade lift down EPC: Short circuit ...........................................................................................1302 Failure code [DXHSKY] Blade lift down EPC: Hot short ...............................................................................................1303 Failure code [DXHTKA] Blade tilt left EPC: Open ....................................................................................................1305 Failure code [DXHTKB] Blade tilt left EPC: Short circuit ...........................................................................................1307 Failure code [DXHTKY] Blade tilt left EPC: Hot short ...............................................................................................1308 Failure code [DXHUKA] Blade tilt right EPC: Open ...................................................................................................1310 Failure code [DXHUKB] Blade tilt right EPC: Short circuit ..........................................................................................1312 Failure code [DXHUKY] Blade tilt right EPC: Hot short ..............................................................................................1313 Failure code [DXJ4KA] Weq lock Sol.: Open ..........................................................................................................1315 Failure code [DXJ4KB] Weq lock Sol.: Short circuit .................................................................................................1317 Failure code [DXJCKA] Blade angle left EPC: Open ...................................................................................................1319 Failure code [DXJCKB] Blade angle left EPC: Short circuit ..........................................................................................1320 Failure code [DXJCKY] Blade angle left EPC: Hot short ..............................................................................................1321 Failure code [DXJDKA] Blade angle right EPC: Open ..................................................................................................1323 Failure code [DXJDKB] Blade angle right EPC: Short circuit .........................................................................................1324 Failure code [DXJDKY] Blade angle right EPC: Hot short .............................................................................................1325 Failure code [DXK1KA] Left HST motor EPC: Open .....................................................................................................1327 Failure code [DXK1KB] Left HST motor EPC: Short circuit ............................................................................................1329 Failure code [DXK1KY] Left HST motor EPC: Hot Short ................................................................................................1330 Failure code [DXK2KA] Right HST motor EPC: Open ....................................................................................................1332 Failure code [DXK2KB] Right HST motor EPC: Short circuit ...........................................................................................1334 Failure code [DXK2KY] Right HST motor EPC: Hot Short ...............................................................................................1335 Troubleshooting of electrical system (E-mode) ..........................................................................................................1337 E-1 Engine does not start (Engine does not crank) ..................................................................................................1337 E-2 Manual preheating system does not work .........................................................................................................1343 E-3 Automatic preheating system does not work ......................................................................................................1346 E-4 While preheating is working, preheating monitor does not light up ..............................................................................1348 E-5 When starting switch is turned to ON position, machine monitor displays nothing ................................................................1350 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up .............................................1353 E-7 Air cleaner clogging monitor lights up in yellow while engine is running .......................................................................1354 E-8 Charge level monitor lights up in red while engine is running ..................................................................................1355 E-9 Engine coolant temperature monitor lights up in red while engine is running ....................................................................1356 E-10 Engine oil pressure monitor lights up in red while engine is running ..........................................................................1357 E-11 HST charge pressure monitor lights up in red while engine is running ..........................................................................1358 E-12 Hydraulic oil temperature monitor lights up in red while engine is running ....................................................................1359 E-13 HST oil filter clogging monitor lights up in red while engine is running ......................................................................1360 E-14 Fuel level gauge does not indicate correct level ..............................................................................................1361 E-15 Engine coolant temperature gauge does not indicate correct temperature ........................................................................1364 E-16 Hydraulic oil temperature gauge does not indicate correct temperature .........................................................................1365 E-17 Operation mode does not change ................................................................................................................1366 E-18 Service mode cannot be selected ...............................................................................................................1367 E-19 Operating customize switch does not display customize screen ..................................................................................1368 E-20 Modifying setting on customize screen does not change setting of machine ......................................................................1369 E-21 Service meter is not displayed, while starting switch is in OFF position ......................................................................1370 E-22 Work equipment does not operate ...............................................................................................................1371 E-23 Foot heater does not operate ..................................................................................................................1373 E-24 Horn does not sound ...........................................................................................................................1378 E-25 Horn does not stop sounding ...................................................................................................................1380 E-26 Backup alarm does not sound ...................................................................................................................1381 E-27 Backup alarm does not stop sounding ...........................................................................................................1382 E-28 Headlamp does not light up ....................................................................................................................1383 E-29 Rear lamp does not light up ...................................................................................................................1386 E-30 No wiper operates continuously or intermittently ..............................................................................................1389 E-31 Front wiper does not operate ..................................................................................................................1391 E-32 Rear wiper does not operate ...................................................................................................................1393 E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) ......................................................1395 E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) .....................................................1399 E-35 Front washer does not operate .................................................................................................................1403 E-36 Rear washer does not operate ..................................................................................................................1405 E-37 Left door washer does not operate .............................................................................................................1407 E-38 Right door washer does not operate ............................................................................................................1409 E-39 KOMTRAX system does not operate normally ......................................................................................................1411 E-40 iB monitor shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] ...........................1413 E-41 iB monitor displays the messages [GPS receiver not connected!] and [Slope sensor not connected!] ..............................................1417 E-42 iB monitor displays the message [Waiting for radio link...] ...................................................................................1420 E-43 iB monitor displays the message [IMU sensor not connected] ....................................................................................1421 E-44 iB monitor displays the message [Waiting for satellites...] ...................................................................................1422 E-45 iB monitor displays the message [Komatsu controller not connected!] ...........................................................................1423 E-46 iB monitor displays the message [Cylinder Stroke Reading Abnormal] ............................................................................1425 E-47 iB monitor displays the message [Komatsu CAN Comms Abnormal] ..................................................................................1426 E-48 iB monitor displays the message [Komatsu Machine Trouble] .....................................................................................1427 E-49 iB monitor displays the message [Waiting to initialize...] ....................................................................................1428 E-50 iB monitor displays the message [System Initializing...] ......................................................................................1429 E-51 iB monitor displays the message [Initializing...] .............................................................................................1430 E-52 iB monitor displays the message [Configuring GPS] .............................................................................................1431 E-53 iB monitor displays the message [No GPS Localization...] ......................................................................................1432 E-54 iB monitor displays the message [Low precisions...] ...........................................................................................1433 E-55 iB monitor displays the message [Heading Initializing] ........................................................................................1434 E-56 iB monitor displays [Out of design area...] ...................................................................................................1435 E-57 iB monitor can not be turned on ...............................................................................................................1436 E-58 iB monitor does not display intelligent Machine Control screen ................................................................................1437 E-59 iB monitor does not display bulldozer image ...................................................................................................1438 E-60 iB monitor does not display design surface ....................................................................................................1439 E-61 iB monitor touch panel does not respond .......................................................................................................1440 E-62 iB monitor touch panel is inaccurate ..........................................................................................................1441 E-63 Cylinder stroke reset indication does not go out ..............................................................................................1442 E-64 AUTO is not displayed when auto/manual switch is pressed (AUTO indication goes out) ...........................................................1443 E-65 Blade automatic lower control does not start while AUTO is displayed ..........................................................................1444 E-66 Blade automatic raise control does not start while AUTO is displayed ..........................................................................1445 E-67 Blade automatic control function is not activated while AUTO is displayed (Blade automatic control stops) .....................................1446 E-68 When checking and adjusting the blade elevation, the value is different from actual machine ...................................................1447 E-69 Finished surface is inaccurate (The average height of finished surface is lower than designed surface or blade does not touch the surface) ....1448 E-70 Finished surface is inaccurate (The finished surface is not smooth) ...........................................................................1449 E-71 Finished surface is inaccurate (When finishing slope horizontally, steps are made in each direction) ..........................................1450 E-72 Machine can not escape from shoes slip while blade automatic control is activated (Shoes frequently slips) ....................................1452 E-73 Machine speed does not increase while blade automatic control is activated ....................................................................1453 E-74 Blade tilt angle does not coincide with design surface ........................................................................................1454 E-75 Blade tilts back while blade automatic control is activated ...................................................................................1456 Troubleshooting of hydraulic and mechanical system (H-mode) ............................................................................................1459 Information described in troubleshooting table (H-mode) ............................................................................................1459 System chart of hydraulic and mechanical systems ...................................................................................................1460 Failure mode and cause table .......................................................................................................................1462 H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) ...........................................1466 H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) .........................................1468 H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate) ................1469 H-4 Travel speed or power is low ...................................................................................................................1471 H-5 Travel speed range does not change .............................................................................................................1472 H-6 Shock is large when machine starts or stops ....................................................................................................1473 H-7 Machine deviates largely .......................................................................................................................1474 H-8 Machine drift on a slope is large ..............................................................................................................1476 H-9 Engine stalls during travel or engine speed drops significantly ................................................................................1477 H-10 Unusual noise is heard from around HST pump or motor ..........................................................................................1478 H-11 All work equipment do not operate .............................................................................................................1479 H-12 All work equipment operates slowly or lacks power .............................................................................................1481 H-13 Blade lift speed or power is low ..............................................................................................................1482 H-14 Blade tilt speed or power is low ..............................................................................................................1483 H-15 Blade angle speed or power is low .............................................................................................................1484 H-16 Time lag of blade lift is large ...............................................................................................................1485 H-17 Hydraulic drift of lifted blade is large ......................................................................................................1486 H-18 Hydraulic drift of tilted blade is large ......................................................................................................1487 H-19 Unusual noise is heard from around work equipment pump or control valve .......................................................................1488 H-20 HST oil temperature (hydraulic oil temperature) rises too high ................................................................................1489 H-21 Fans speed is abnormal (high, low, or no rotation) ............................................................................................1491 H-22 Unusual noise is heard from around fan ........................................................................................................1493 Troubleshooting of engine (S-mode) .....................................................................................................................1494 Information described in troubleshooting table (S mode) ............................................................................................1494 S-1 Engine does not crank when starting switch is turned to START position .........................................................................1495 S-2 Engine cranks but no exhaust smoke comes out ...................................................................................................1496 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .................................................1497 S-4 Engine startability is poor ....................................................................................................................1498 S-5 Engine does not pick up smoothly ...............................................................................................................1500 S-6 Engine stops during operation ..................................................................................................................1502 S-7 Engine runs rough or is unstable ...............................................................................................................1504 S-8 Engine lacks power .............................................................................................................................1505 S-9 KDPF gets clogged in a short time ..............................................................................................................1507 S-10 Engine oil consumption is excessive ...........................................................................................................1509 S-11 Engine oil becomes contaminated early .........................................................................................................1510 S-12 Fuel consumption is excessive .................................................................................................................1511 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ..............................................................................1512 S-14 Oil pressure drops ............................................................................................................................1513 S-15 Fuel mixes into engine oil ....................................................................................................................1514 S-16 Water mixes into engine oil (milky) ...........................................................................................................1515 S-17 Coolant temperature rises too high (overheating) ..............................................................................................1516 S-18 Unusual noise is heard ........................................................................................................................1517 S-19 Vibration is excessive ........................................................................................................................1518 S-20 Air cannot be bled from fuel circuit ..........................................................................................................1519 S-21 Active regeneration is executed frequently ....................................................................................................1520 S-22 Active regeneration takes time ................................................................................................................1521 S-23 White smoke is exhausted during active regeneration ...........................................................................................1522 50 Disassembly and assembly ................................................................................................................................1523 Table of contents ......................................................................................................................................1524 Related information on disassembly and assembly ........................................................................................................1526 How to read this manual ............................................................................................................................1526 Coating materials list .............................................................................................................................1528 Special tools list .................................................................................................................................1532 Sketches of special tools ..........................................................................................................................1538 Engine and cooling system ..............................................................................................................................1552 Removal and installation of supply pump assembly ...................................................................................................1552 Removal and installation of fuel injector assembly .................................................................................................1557 Removal and installation of cylinder head assembly .................................................................................................1565 Removal and installation of radiator assembly ......................................................................................................1581 Removal and installation of aftercooler assembly ...................................................................................................1585 Removal and installation of hydraulic oil cooler assembly ..........................................................................................1588 Removal and installation of cooling fan drive assembly .............................................................................................1591 Removal and installation of cooling fan motor assembly .............................................................................................1594 Removal and installation of engine assembly ........................................................................................................1596 Disassembly and assembly of damper assembly ........................................................................................................1603 Removal and installation of engine front oil seal ..................................................................................................1604 Removal and installation of engine rear oil seal ...................................................................................................1606 Removal and installation of engine hood assembly ...................................................................................................1609 Removal and installation of fuel tank assembly .....................................................................................................1612 Removal and installation of KDPF assembly ..........................................................................................................1616 Disassembly and assembly of KDPF assembly ..........................................................................................................1619 Removal and installation of KCCV assembly ..........................................................................................................1628 Removal and installation of KVGT assembly ..........................................................................................................1629 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ........................................................................1632 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly .........................................................................1635 Removal and installation of belt for alternator and air conditioner compressor .....................................................................1636 Removal and installation of air cleaner assembly ...................................................................................................1637 Power train ............................................................................................................................................1639 Removal and installation of HST pump assembly ......................................................................................................1639 Removal and installation of HST motor and final drive assembly .....................................................................................1641 Disassembly and assembly of final drive ............................................................................................................1644 Undercarriage and frame ................................................................................................................................1654 Removal and installation of track frame assembly ...................................................................................................1654 Removal and installation of idler assembly .........................................................................................................1658 Disassembly and assembly of idler ..................................................................................................................1660 Removal and installation of recoil spring assembly .................................................................................................1664 Disassembly and assembly of recoil spring ..........................................................................................................1665 Removal and installation of track roller assembly ..................................................................................................1669 Disassembly and assembly of track roller assembly ..................................................................................................1671 Removal and installation of carrier roller assembly ................................................................................................1674 Disassembly and assembly of carrier roller assembly ................................................................................................1676 Removal and installation of segment teeth ..........................................................................................................1678 Separation and connection of track shoe assembly (Standard type track shoe) ........................................................................1679 Separation and connection of track shoe assembly (PLUS type track shoe) ............................................................................1682 Overall disassembly and assembly of track shoe assembly (Standard type track shoe) .................................................................1683 Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) .....................................................................1699 Disassembly and assembly of one track link assembly in field (Standard type track shoe) ............................................................1706 Disassembly and assembly of one track link assembly in field (PLUS type track shoe) ................................................................1712 Removal and installation of pivot shaft assembly ...................................................................................................1717 Removal and installation of equalizer bar assembly .................................................................................................1719 Removal and installation of equalizer bar side bushing .............................................................................................1721 Hydraulic system .......................................................................................................................................1722 Removal and installation of hydraulic tank assembly ................................................................................................1722 Removal and installation of control valve assembly .................................................................................................1726 Disassembly and assembly of hydraulic cylinder assembly ............................................................................................1729 Work equipment .........................................................................................................................................1737 Removal and installation of work equipment assembly ................................................................................................1737 Removal and installation of blade assembly .........................................................................................................1740 Removal and installation of U-frame assembly .......................................................................................................1742 Cab and its attachments ................................................................................................................................1745 Removal and installation of ROPS cab assembly ......................................................................................................1745 Removal and installation of operator's cab glass (adhesion glass) ..................................................................................1750 Removal and installation of operator's seat ........................................................................................................1756 Removal and installation of seat belt ..............................................................................................................1757 Removal and installation of foot heater assembly ...................................................................................................1758 Disassembly and assembly of foot heater assembly ...................................................................................................1760 Removal and installation of air conditioner unit assembly ..........................................................................................1761 Removal and installation of air conditioner compressor assembly ....................................................................................1765 Electrical system ......................................................................................................................................1767 Removal and installation of machine monitor assembly ...............................................................................................1767 Removal and installation of engine controller assembly .............................................................................................1768 Removal and installation of HST controller assembly ................................................................................................1770 Removal and installation of mass air flow and temperature sensor ...................................................................................1771 Removal and installation of KOMTRAX terminal .......................................................................................................1772 Removal and installation of ICT sensor controller assembly .........................................................................................1773 Removal and installation of iB monitor .............................................................................................................1774 Removal and installation of GNSS receiver ..........................................................................................................1775 Removal and installation of iB GNSS antenna ........................................................................................................1776 Removal and installation of IMU sensor .............................................................................................................1779 60 Maintenance standard ....................................................................................................................................1781 Table of contents ......................................................................................................................................1782 Engine and cooling system ..............................................................................................................................1783 Engine mount .......................................................................................................................................1783 Cooling fan motor ..................................................................................................................................1784 Oil cooler bypass and HST charge safety valve ......................................................................................................1786 Power train ............................................................................................................................................1787 Damper .............................................................................................................................................1787 HST pump ...........................................................................................................................................1788 HST motor ..........................................................................................................................................1790 Charge pump ........................................................................................................................................1791 Solenoid valve .....................................................................................................................................1792 Final drive ........................................................................................................................................1793 Sprocket ...........................................................................................................................................1794 Full-scale drawing of sprocket tooth profile .......................................................................................................1795 Undercarriage and frame ................................................................................................................................1797 Suspension .........................................................................................................................................1797 Track frame and idler cushion ......................................................................................................................1799 Idler ..............................................................................................................................................1801 Track roller .......................................................................................................................................1803 Carrier roller .....................................................................................................................................1807 Track shoe .........................................................................................................................................1809 Hydraulic system .......................................................................................................................................1815 Hydraulic tank .....................................................................................................................................1815 Work equipment and cooling fan pump ................................................................................................................1816 Control valve ......................................................................................................................................1819 Ripper PPC valve ...................................................................................................................................1826 Quick drop valve ...................................................................................................................................1828 Angle control EPC valve ............................................................................................................................1830 Work equipment .........................................................................................................................................1831 Blade ..............................................................................................................................................1831 Cutting edge and end bit ...........................................................................................................................1834 Ripper .............................................................................................................................................1835 Lift cylinder ......................................................................................................................................1837 Lift cylinder with stroke and reset sensor .........................................................................................................1838 Tilt cylinder with stroke sensor ...................................................................................................................1839 Angle cylinder .....................................................................................................................................1840 Angle cylinder with stroke and reset sensor ........................................................................................................1841 Ripper cylinder ....................................................................................................................................1842 Cab and its attachments ................................................................................................................................1843 Cab mount ..........................................................................................................................................1843 Electrical system ......................................................................................................................................1844 System component parts .............................................................................................................................1844 Sensor .............................................................................................................................................1845 80 Appendix ................................................................................................................................................1849 Table of contents ......................................................................................................................................1850 Air conditioner components .............................................................................................................................1851 Precautions for refrigerant ........................................................................................................................1851 Air conditioner component ..........................................................................................................................1852 Configuration and function of refrigeration cycle ..................................................................................................1855 Outline of refrigeration cycle .....................................................................................................................1856 Air conditioner unit ...............................................................................................................................1858 Dual pressure switch ...............................................................................................................................1862 Pressure switch ....................................................................................................................................1863 Compressor .........................................................................................................................................1864 Condenser ..........................................................................................................................................1865 Receiver drier .....................................................................................................................................1867 Procedure for testing and troubleshooting ..........................................................................................................1868 Electrical circuit diagram .........................................................................................................................1871 System diagram .....................................................................................................................................1872 Parts and connectors layout ........................................................................................................................1874 Testing relays .....................................................................................................................................1879 Troubleshooting chart 1 ............................................................................................................................1881 Troubleshooting chart 2 ............................................................................................................................1882 Information described in troubleshooting table .....................................................................................................1884 A-1 Troubleshooting for condenser fan ..............................................................................................................1885 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ......................................................................1888 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .............................................................1892 A-4 Troubleshooting for temperature control ........................................................................................................1894 Troubleshooting with gauge pressure ................................................................................................................1897 Connection of service tool .........................................................................................................................1900 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ............................................................1902 Handling of compressor oil .........................................................................................................................1904 90 Diagrams and drawings ...................................................................................................................................1907 Table of contents ......................................................................................................................................1908 Hydraulic circuit diagram ..............................................................................................................................1909 Symbols in hydraulic circuit diagram ...............................................................................................................1909 Hydraulic circuit diagram ..........................................................................................................................1913 Electric circuit diagram ...............................................................................................................................1914 Symbols in electric circuit diagram ................................................................................................................1914 Electrical circuit diagram .........................................................................................................................1918 INDEX.......................................................................................................................................................1928
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