Komatsu D61EXi-24 D61EXi-24E0 D61PXi-24 D61PXi-24E0 Bulldozer Shop Manual PDF

Description

Komatsu D61EXi-24 D61EXi-24E0 D61PXi-24 D61PXi-24E0 Bulldozer Shop Manual SEN06856-07 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D61EXi-24 D61EXi-24E0 D61PXi-24 D61PXi-24E0 Bulldozer Shop Manual SEN06856-07 – PDF DOWNLOAD 

Language : English
Pages : 3342
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu D61EXi-24 D61EXi-24E0 D61PXi-24 D61PXi-24E0 Bulldozer Shop Manual SEN06856-07 – PDF DOWNLOAD 

SERIAL NUMBERS

D61EXi-45001 and up
D61PXi-45001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

TABLE OF CONTENTS:

Komatsu D61EXi-24 D61EXi-24E0 D61PXi-24 D61PXi-24E0 Bulldozer Shop Manual SEN06856-07 – PDF DOWNLOAD 

SERIAL NUMBERS

D61EXi-45001 and up
D61PXi-45001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 22
Foreword, Safety, Basic Information 25
How to Read the Shop Manual 25
Safety Notice for Operation 27
Precautions to Prevent Fire 35
Procedures If Fire Occurs 37
Precautions for Disposing of Waste Materials 38
Procedures for Exhaust Gas Regulations 39
Precautions for DEF 40
General Character and Precautions for Handling 40
Precautions for Adding 40
Precautions for Storage 40
Precautions for Fire Hazard and Leakage 40
Other Precautions 40
Store DEF 41
Precautions When You Handle Hydraulic Equipment 42
Precautions When You Disconnect and Connect Pipings 45
Precautions When You Handle Electrical Equipment 52
Precautions When You Handle Fuel System Equipment 54
Precautions When You Handle Intake System Equipment 55
Practical Use of KOMTRAX 56
Disconnect and Connect Push-Pull Type Coupler 57
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 59
Precautions for Disconnection and Connection of Connectors 61
How to Disconnect and Connect Deutsch Connector 65
How to Disconnect and Connect Slide Lock Type Connector 66
How to Disconnect and Connect Connector with Lock to Pull 68
How to Disconnect and Connect Connector with Lock to Push 69
How to Disconnect and Connect Connector with Housing to Rotate 71
How to Read the Codes for Electric Cable 72
Explanation of Terms for Maintenance Standard 76
Standard Tightening Torque Table 79
Conversion Table 86
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: D155CX-8 93
Specifications 95
Specifications: D155CX-8 95
Weight Table 99
Weight Table: D155CX-8 99
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System 107
Urea SCR System Diagram 109
Function of Urea SCR System 110
Function of DEF System 110
Inducement Strategy 113
Component Parts of Urea SCR System 120
DEF Mixing Tube 120
SCR Assembly 120
DEF Tank 123
DEF Pump 125
DEF Injector 126
DEF Hose 127
DEF Tank Heating Valve 128
Boot-up System 129
Layout Drawing of Boot-up System 129
System Operating Lamp System 130
System Diagram of System Operating Lamp System 130
Function of Operation Lamp System 130
Battery Disconnect Switch 132
Layout Drawing of Battery Disconnect Switch 132
Function of Battery Disconnect Switch 132
Engine System 134
Layout Drawing of Engine System 134
Engine Control System 136
Layout Drawing of Engine Control System 136
System Diagram of Engine Control 137
Function of Engine Control System 138
Automatic Idle Stop System 139
System Diagram of Automatic Idle Stop System 139
Function of Automatic Idle Stop System 139
Component Parts of Engine System 142
Damper 142
VGT 143
EGR System 147
EGR Valve 149
EGR Cooler 151
KCCV System 153
KCCV Ventilator 155
KDPF 158
Cooling System 162
Layout Drawing of Cooling System 162
Specifications of Cooling System 163
Component Parts of Cooling System 164
Cooling Fan Pump 164
Cooling Fan Motor 172
Hydraulic Oil Cooler Bypass Valve 179
Control System 180
Layout Drawing of Control System 180
Machine Monitor System 181
System Diagram of Machine Monitor System 181
Function of Machine Monitor System 181
KOMTRAX System 184
System Diagram of KOMTRAX System 184
Function of KOMTRAX System 184
Component Parts of Control System 185
Machine Monitor 185
Gateway Function Controller 200
Communication Terminal 203
Power Train Controller 205
Work Equipment Controller 209
Engine Controller 213
Fuel Feed Pump 219
Fuel Feed Pump Switch 220
Hydraulic System 221
Layout Drawing of Hydraulic System 221
CLSS 222
Structure of CLSS 222
Function of CLSS 223
Component Parts of Hydraulic System 225
Hydraulic Tank 225
Work Equipment and HSS Pump 226
LS Valve 231
PC Valve 236
PC-EPC Valve 241
Control Valve 244
Power Train System 280
Layout Drawing of Power Train System 280
Operation of Power Train System 282
Transmission, Steering, and Brake Control 283
Layout Drawing of Transmission, Steering, and Brake Control System 283
Function of Transmission, Steering, and Brake Control System 284
Palm Command Control System 285
Palm Command Control System Diagram 285
HSS System 287
HSS System Diagram 287
Function of HSS System 288
Centralized Pressure Pickup Port 290
Layout Drawing of Centralized Pressure Pickup Port 290
Function of Centralized Pressure Pickup Port 291
Component Parts of Power Train System 292
Universal Joint 292
Power Train Mount 293
Torque Converter and PTO 294
Torque Converter Control Valve 300
ECMV (Lockup Clutch Valve) 301
ECMV (Stator Clutch Valve) 304
Transmission 308
ECMV (Transmission) 318
Main Relief Valve and Torque Converter Relief Valve 325
Transmission Lubrication Relief Valve 327
Bevel Gear Shaft, HSS, and Brake 327
Final Drive 355
Single Pump (Scavenging) 358
Duplex Pump (Lubrication, Power Train) 359
HSS Motor 360
Electric Steering Electric Lever 367
Work Equipment System 372
Work Equipment Control 372
Layout Drawing of Work Equipment Control 372
Function of Work Equipment Control 373
Component Parts of Work Equipment System 374
Self-Pressure Reducing Valve 374
Work Equipment Lock Solenoid Valve 380
Pilot Circuit Accumulator 382
Work Equipment Electric Lever 383
Rear Work Equipment Electric Lever 384
Undercarriage and Frame 385
Main Frame 385
Structure of Main Frame 385
Suspension 386
Structure of Suspension 386
Function of Suspension 388
Track Frame and Idler Cushion 389
Structure of Track Frame and Idler Cushion 389
Specifications of Track Frame and Idler Cushion 390
Function of Track Frame and Idler Cushion 390
CAB Related Parts 391
ROPS CAB 391
Structure of ROPS CAB 391
Function of ROPS CAB 391
CAB Mount 392
Structure of CAB Mount 392
20 Standard Value Table 393
Table of Contents 394
Standard Value Table for Engine 395
Standard Value Table for Engine: D155CX-8 395
Standard Value Table for Machine 399
Standard Value Table for Machine: D155CX-8 399
30 Testing and Adjusting 411
Table of Contents 412
Precautions Before Work 415
Related Information on Testing and Adjusting 416
Tools for Testing and Adjusting 416
Sketch of Tools for Testing and Adjusting 424
Engine and Cooling System 427
Examine Engine Speed 427
How to Examine Engine Speed 427
Examine Boost Pressure 433
How to Examine Boost Pressure 433
Examine Exhaust Gas Temperature 435
How to Examine Exhaust Gas Temperature 435
Examine Exhaust Gas Color 440
How to Examine Exhaust Gas Color with the Handy Smoke Checker 440
How to Examine Exhaust Gas Color with Smoke Meter 441
Examine Mass Air Flow and Temperature Sensor 443
How to Examine Mass Air Flow and Temperature Sensor 443
Examine and Adjust Valve Clearance 445
How to Examine Valve Clearance 445
How to Adjust Valve Clearance 446
Examine Compression Pressure 448
How to Examine Compression Pressure 448
Examine Blowby Pressure 451
How to Examine Blowby Pressure 451
Examine Engine Oil Pressure 453
How to Examine Engine Oil Pressure on Machine Monitor 453
How to Examine Engine Oil Pressure by Testing Tool 453
Examine EGR Valve and VGT Oil Pressure 455
How to Examine EGR Valve and VGT Oil Pressure 455
Examine Fuel Pressure 457
How to Examine Fuel Pressure 457
Examine Fuel Return Rate and Leakage 459
How to Examine Fuel Return Rate and Leakage 460
Bleed Air from Fuel System 465
How to Bleed Air from Fuel System 465
Examine Fuel Circuit for Leakage 467
How to Examine Fuel System for Leakage 467
Handle Cylinder Cut-out Mode Operation 469
Handle No-Injection Cranking Operation 470
Clean Fuel Doser 471
How to Clean Fuel Doser 471
Write Injector Compensation Value to Engine Controller 473
How to Write Injector Compensation Value 473
Write Correction for Ash in Soot Accumulation to Engine Controller 479
How to Write Correction for Ash in Soot Accumulation to Engine Controller 479
Examine SCR Related Functions 480
Examine DEF Pump Raised Pressure 484
Examine Injection Volume from DEF Injector 487
Examine DEF Line Heater Relay 1 492
Examine DEF Line Heater Relay 2 495
Examine DEF Pump Heater Relay 498
Examine DEF Tank Heater Valve 502
Examine SCR Denitration Efficiency 505
Clean DEF Tank 508
How to Clean DEF Tank 509
Clean DEF Pump 515
How to Clean DEF Pump 515
Adjust Decelerator Pedal 522
How to Adjust Decelerator Pedal 522
Power Train 525
Examine Power Train Oil Pressure 525
How to Examine Power Train Oil Pressure 526
Adjust Transmission Output Shaft Speed Sensor 536
How to Adjust Transmission Output Shaft Speed Sensor 536
Examine Brake Performance Simply 537
How to Examine Brake Performance Simply 537
Examine and Adjust Brake Pedal 538
How to Examine Brake Pedal 538
How to Adjust Brake Pedal 539
Adjust Parking Brake Lever 542
How to Adjust Parking Brake Lever 542
Move Machine by Parking Brake Release When Machine Does Not Travel 544
How to Move Machine with Hydraulic Type Parking Brake Release System 544
How to Move Machine with Electric Type Parking Brake Release System 545
Undercarriage and Frame 548
Adjust Idler Clearance 548
How to Adjust Idler Clearance 548
Examine and Adjust Track Tension 551
How to Examine Track Tension 551
How to Adjust Track Tension 551
Hydraulic System 553
Release Remained Pressure in Hydraulic Circuit 553
How to Release Remained Pressure in Hydraulic System 553
Examine and Adjust Work Equipment and HSS Oil Pressure 554
How to Examine Work Equipment and HSS Oil Pressure 554
How to Adjust Oil Pressure of Work Equipment and HSS 557
Examine Oil Pressure of Control Circuit 560
How to Examine Oil Pressure in Control Circuit 560
Examine Work Equipment Lock Solenoid Valve Outlet Pressure 562
How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure 562
Examine Outlet Pressure in Solenoid Valve of Rear Work Equipment Switch 564
How to Examine Outlet Pressure in Solenoid Valve of Rear Work Equipment Switch 564
Bleed Air from Work Equipment and HSS Pump 566
How to Bleed Air from Work Equipment and HSS Pump 566
Examine Cooling Fan Speed 567
How to Examine Cooling Fan Speed 567
Examine Cooling Fan Circuit Oil Pressure 568
How to Examine Cooling Fan Circuit Oil Pressure 568
Bleed Air in Cooling Fan Pump 570
How to Bleed Air in Cooling Fan Pump 570
Operation When Work Equipment is Disabled 571
How to Operate When Work Equipment is Disabled 571
Work Equipment 574
Adjust Work Equipment Lock Lever 574
How to Adjust Work Equipment Lock Lever 574
Examine and Adjust Play of Blade Electric Lever 576
How to Examine Play of Blade Electric Lever 578
How to Adjust Play of Blade Electric Lever 578
How to Replace Universal Joint 579
CAB Related Parts 586
Examine and Adjust Operator Cab 586
How to Examine Operator Cab 586
How to Adjust Operator Cab 589
Electrical System 591
Set and Operate Machine Monitor 591
Operator Mode 594
Function to Show Technician Identification Status Screen 594
Function to Show Operator Identification Input Screen 594
Examine Function by LCD (Liquid Crystal Display) 595
Examine Function of Service Meter 596
How to Set Usage Limitation and Change Maintenance Password 596
Service Mode 598
How to Operate Service Mode 598
How to See Pre-defined Monitoring Information 600
How to Examine Self-Define Monitor Information 606
Abnormality Record Menu 618
How to See Maintenance Record 622
Maintenance Mode Setting 623
How to Set Phone Number Entry 627
Default Menu 628
Diagnostic Tests Menu 635
Adjustment Menu 644
No-Injection Cranking Operation 693
KOMTRAX Settings Menu 695
How to Show Service Message 697
How to Start Up KOMTRAX Terminal 699
Adjust Rearview Camera Angle 705
How to Adjust Rearview Camera Angle 705
Handle Voltage Circuit of Engine Controller 706
Handle Battery Disconnect Switch 707
Examine Diodes 708
How to Examine Diodes by Digital Tester 708
How to Examine Diodes by Analog Tester 708
Pm Clinic 709
Pm Clinic Service 709
Pm Clinic Check Sheet 711
Pm Clinic Check Sheet for Undercarriage 722
40 Troubleshooting 725
Table of Contents 726
Precautions Before Work 738
Related Information to Troubleshooting 739
General Troubleshooting Points 739
Troubleshooting Points for Urea SCR System 740
Sequence of Events in Troubleshooting 752
Checks Before Troubleshooting 754
Inspection Procedure Before Troubleshooting 756
Walk-Around Check 756
Test in Accordance with Testing Procedure 758
Examine Fuel Level and Type 758
Examine for Impure Ingredient in Fuel 758
Examine DEF Level and Type 759
Examine Fuel Prefilter 759
Examine Fuel Main Filter 761
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 762
Examine Coolant Level (Reservoir Tank) 763
Examine Air Cleaner Clogging 764
Clean Outer Element 764
Replace Element 766
Examine Hydraulic Oil Level 767
Examine Hydraulic Oil Strainer 768
Examine Hydraulic Oil Filter 768
Examine Oil Level in Power Train Case 769
Examine Power Train Strainer 771
Examine Power Train Filter 772
Examine Oil Level in Damper Case 772
Examine Oil Level in Final Drive Case 773
How to Examine Electric Equipment 774
Procedure for Troubleshooting 781
Symptom and Troubleshooting Numbers 784
Information Shown in Troubleshooting Table 787
Connector List and Layout 789
Connector Contact Connection Table 805
T-Branch Box and T-Branch Adapter Table 845
Fuse Location Table 851
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 854
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 858
Failure Code Table 860
Troubleshooting by Failure Code (Display of Code) 883
Failure Code [1500L0] 883
Failure Code [15SAL1] 884
Failure Code [15SALH] 886
Failure Code [15SBL1] 888
Failure Code [15SBLH] 890
Failure Code [15SEL1] 892
Failure Code [15SELH] 894
Failure Code [15SFL1] 896
Failure Code [15SFLH] 898
Failure Code [15SGL1] 900
Failure Code [15SGLH] 902
Failure Code [15SJL1] 904
Failure Code [15SJLH] 906
Failure Code [1800MW] 908
Failure Code [2300NR] 909
Failure Code [2301L1] 910
Failure Code [2301LH] 912
Failure Code [2302L1] 914
Failure Code [2302LH] 916
Failure Code [879AKA] 918
Failure Code [879AKB] 919
Failure Code [879BKA] 920
Failure Code [879BKB] 922
Failure Code [879CKA] 924
Failure Code [879CKB] 925
Failure Code [879DKZ] 926
Failure Code [879EMC] 928
Failure Code [879FMC] 929
Failure Code [879GKX] 930
Failure Code [989L00] 932
Failure Code [989M00] 933
Failure Code [989N00] 934
Failure Code [A1U0N3] 935
Failure Code [A1U0N4] 937
Failure Code [A900FR] 939
Failure Code [A900N6] 940
Failure Code [A900NY] 941
Failure Code [AA10NX] 942
Failure Code [AB00KE] 944
Failure Code [AQ10N3] 946
Failure Code [AS00N3] 948
Failure Code [AS00R2] 950
Failure Code [AS00R3] 951
Failure Code [AS00R4] 952
Failure Code [AS00R5] 953
Failure Code [AS00R6] 954
Failure Code [AS00ZK] 955
Failure Code [AS10KM] 956
Failure Code [AS10NR] 957
Failure Code [AS10NT] 958
Failure Code [B@BAZG] 959
Failure Code [B@BCNS] 960
Failure Code [B@BCQA] 961
Failure Code [B@BCZK] 963
Failure Code [B@CENS] 965
Failure Code [B@HANS] 966
Failure Code [CA115] 967
Failure Code [CA122] 968
Failure Code [CA123] 970
Failure Code [CA131] 972
Failure Code [CA132] 974
Failure Code [CA135] 976
Failure Code [CA141] 978
Failure Code [CA144] 980
Failure Code [CA145] 982
Failure Code [CA153] 984
Failure Code [CA154] 987
Failure Code [CA187] 990
Failure Code [CA221] 992
Failure Code [CA222] 994
Failure Code [CA227] 996
Failure Code [CA234] 997
Failure Code [CA238] 998
Failure Code [CA239] 1000
Failure Code [CA249] 1002
Failure Code [CA256] 1004
Failure Code [CA271] 1006
Failure Code [CA272] 1008
Failure Code [CA273] 1009
Failure Code [CA274] 1011
Failure Code [CA322] 1012
Failure Code [CA323] 1014
Failure Code [CA324] 1016
Failure Code [CA325] 1018
Failure Code [CA331] 1020
Failure Code [CA332] 1022
Failure Code [CA343] 1024
Failure Code [CA351] 1025
Failure Code [CA352] 1026
Failure Code [CA356] 1029
Failure Code [CA357] 1031
Failure Code [CA386] 1034
Failure Code [CA441] 1035
Failure Code [CA442] 1038
Failure Code [CA449] 1039
Failure Code [CA451] 1040
Failure Code [CA452] 1042
Failure Code [CA515] 1044
Failure Code [CA516] 1046
Failure Code [CA553] 1048
Failure Code [CA555] 1049
Failure Code [CA556] 1050
Failure Code [CA559] 1051
Failure Code [CA595] 1056
Failure Code [CA687] 1057
Failure Code [CA689] 1059
Failure Code [CA691] 1061
Failure Code [CA692] 1063
Failure Code [CA697] 1065
Failure Code [CA698] 1066
Failure Code [CA731] 1067
Failure Code [CA778] 1068
Failure Code [CA1117] 1071
Failure Code [CA1664] 1072
Failure Code [CA1669] 1075
Failure Code [CA1673] 1076
Failure Code [CA1677] 1077
Failure Code [CA1678] 1078
Failure Code [CA1682] 1079
Failure Code [CA1683] 1081
Failure Code [CA1684] 1083
Failure Code [CA1686] 1085
Failure Code [CA1691] 1086
Failure Code [CA1694] 1089
Failure Code [CA1695] 1091
Failure Code [CA1696] 1092
Failure Code [CA1712] 1094
Failure Code [CA1713] 1097
Failure Code [CA1714] 1099
Failure Code [CA1715] 1100
Failure Code [CA1776] 1101
Failure Code [CA1777] 1104
Failure Code [CA1843] 1107
Failure Code [CA1844] 1109
Failure Code [CA1879] 1112
Failure Code [CA1881] 1115
Failure Code [CA1883] 1117
Failure Code [CA1885] 1121
Failure Code [CA1887] 1123
Failure Code [CA1921] 1125
Failure Code [CA1922] 1128
Failure Code [CA1923] 1133
Failure Code [CA1924] 1135
Failure Code [CA1925] 1137
Failure Code [CA1927] 1139
Failure Code [CA1928] 1141
Failure Code [CA1942] 1143
Failure Code [CA1963] 1144
Failure Code [CA1977] 1147
Failure Code [CA1993] 1150
Failure Code [CA2185] 1153
Failure Code [CA2186] 1155
Failure Code [CA2249] 1157
Failure Code [CA2265] 1158
Failure Code [CA2266] 1160
Failure Code [CA2271] 1163
Failure Code [CA2272] 1165
Failure Code [CA2349] 1167
Failure Code [CA2353] 1169
Failure Code [CA2357] 1171
Failure Code [CA2381] 1172
Failure Code [CA2382] 1174
Failure Code [CA2383] 1176
Failure Code [CA2386] 1178
Failure Code [CA2387] 1180
Troubleshooting Flowchart 1184
Failure Code [CA2555] 1185
Failure Code [CA2556] 1188
Failure Code [CA2637] 1190
Failure Code [CA2639] 1192
Failure Code [CA2732] 1195
Failure Code [CA2733] 1197
Failure Code [CA2741] 1199
Failure Code [CA2765] 1200
Failure Code [CA2771] 1201
Failure Code [CA2777] 1207
Failure Code [CA2878] 1210
Failure Code [CA2881] 1213
Failure Code [CA2976] 1216
Failure Code [CA3133] 1218
Failure Code [CA3134] 1220
Failure Code [CA3135] 1222
Failure Code [CA3142] 1226
Failure Code [CA3143] 1227
Failure Code [CA3144] 1228
Failure Code [CA3146] 1230
Failure Code [CA3147] 1231
Failure Code [CA3148] 1232
Failure Code [CA3151] 1234
Failure Code [CA3165] 1240
Failure Code [CA3167] 1242
Failure Code [CA3229] 1245
Failure Code [CA3231] 1247
Failure Code [CA3232] 1249
Failure Code [CA3235] 1253
Failure Code [CA3239] 1255
Failure Code [CA3241] 1258
Failure Code [CA3242] 1261
Failure Code [CA3251] 1264
Failure Code [CA3253] 1267
Failure Code [CA3254] 1271
Failure Code [CA3255] 1274
Failure Code [CA3256] 1278
Failure Code [CA3311] 1280
Failure Code [CA3312] 1282
Failure Code [CA3313] 1285
Failure Code [CA3314] 1286
Failure Code [CA3315] 1287
Failure Code [CA3316] 1290
Failure Code [CA3317] 1291
Failure Code [CA3318] 1292
Failure Code [CA3319] 1295
Failure Code [CA3321] 1296
Failure Code [CA3322] 1298
Failure Code [CA3419] 1301
Failure Code [CA3421] 1303
Failure Code [CA3497] 1305
Failure Code [CA3498] 1306
Failure Code [CA3543] 1307
Failure Code [CA3545] 1314
Failure Code [CA3547] 1316
Failure Code [CA3558] 1317
Failure Code [CA3559] 1319
Failure Code [CA3562] 1321
Failure Code [CA3563] 1323
Failure Code [CA3567] 1326
Failure Code [CA3568] 1329
Failure Code [CA3571] 1333
Failure Code [CA3572] 1335
Failure Code [CA3574] 1337
Failure Code [CA3575] 1339
Failure Code [CA3577] 1341
Failure Code [CA3578] 1343
Failure Code [CA3582] 1345
Failure Code [CA3583] 1352
Failure Code [CA3596] 1354
Failure Code [CA3649] 1356
Failure Code [CA3681] 1358
Failure Code [CA3682] 1363
Failure Code [CA3713] 1369
Failure Code [CA3717] 1372
Failure Code [CA3718] 1373
Failure Code [CA3725] 1374
Failure Code [CA3748] 1377
Failure Code [CA3751] 1380
Failure Code [CA3755] 1382
Failure Code [CA3866] 1384
Failure Code [CA3867] 1388
Failure Code [CA3868] 1391
Failure Code [CA3899] 1395
Failure Code [CA3911] 1397
Failure Code [CA3912] 1401
Failure Code [CA3932] 1403
Failure Code [CA3933] 1405
Failure Code [CA3934] 1407
Failure Code [CA3935] 1410
Failure Code [CA3936] 1412
Failure Code [CA4151] 1414
Failure Code [CA4152] 1418
Failure Code [CA4155] 1422
Failure Code [CA4156] 1424
Failure Code [CA4157] 1427
Failure Code [CA4158] 1429
Failure Code [CA4159] 1430
Failure Code [CA4161] 1431
Failure Code [CA4162] 1434
Failure Code [CA4163] 1437
Failure Code [CA4164] 1439
Failure Code [CA4165] 1441
Failure Code [CA4166] 1443
Failure Code [CA4168] 1445
Failure Code [CA4169] 1448
Failure Code [CA4171] 1450
Failure Code [CA4249] 1453
Failure Code [CA4251] 1455
Failure Code [CA4259] 1457
Failure Code [CA4261] 1460
Failure Code [CA4277] 1463
Failure Code [CA4281] 1467
Failure Code [CA4459] 1471
Failure Code [CA4461] 1474
Failure Code [CA4658] 1477
Failure Code [CA4731] 1481
Failure Code [CA4732] 1482
Failure Code [CA4739] 1483
Failure Code [CA4768] 1484
Failure Code [CA4769] 1486
Failure Code [CA4842] 1489
Failure Code [CA4952] 1493
Failure Code [CA5115] 1495
Failure Code [CA5383] 1498
Failure Code [D110KB] 1500
Failure Code [D130KA] 1502
Failure Code [D130KB] 1505
Failure Code [D190KA] 1507
Failure Code [D190KB] 1509
Failure Code [D19JKZ] 1511
Failure Code [D811MC] 1514
Failure Code [D862KA] 1515
Failure Code [D8ALKA] 1516
Failure Code [D8ALKB] 1518
Failure Code [D8AQKR] 1521
Failure Code [D8ARKR] 1523
Failure Code [D8G1KT] 1525
Failure Code [D8G6KT] 1526
Failure Code [DAF0MB] 1527
Failure Code [DAF0MC] 1528
Failure Code [DAF8KB] 1529
Failure Code [DAF9KQ] 1530
Failure Code [DAFGMC] 1531
Failure Code [DAFLKA] 1532
Failure Code [DAFLKB] 1534
Failure Code [DAFQKR] 1537
Failure Code [DAZ9KQ] 1538
Failure Code [DAZQKR] 1539
Failure Code [DB2QKR] 1540
Failure Code [DB2RKR] 1547
Failure Code [DB90KT] 1553
Failure Code [DB90MC] 1554
Failure Code [DB91KK] 1555
Failure Code [DB92KK] 1558
Failure Code [DB95KK] 1560
Failure Code [DB97KK] 1562
Failure Code [DB99KQ] 1564
Failure Code [DB9LKA] 1566
Failure Code [DB9LKB] 1568
Failure Code [DB9QKR] 1570
Failure Code [DB9RKR] 1571
Failure Code [DBE0KT] 1573
Failure Code [DBE0MC] 1574
Failure Code [DBE1KK] 1575
Failure Code [DBE2KK] 1578
Failure Code [DBE5KK] 1581
Failure Code [DBE6KK] 1583
Failure Code [DBE9KQ] 1585
Failure Code [DBELKA] 1586
Failure Code [DBELKB] 1588
Failure Code [DBEQKR] 1591
Failure Code [DBERKR] 1592
Failure Code [DD12KA] 1594
Failure Code [DD12KB] 1596
Failure Code [DD13KA] 1598
Failure Code [DD13KB] 1600
Failure Code [DD14KA] 1602
Failure Code [DD14KB] 1605
Failure Code [DDDDKA] 1607
Failure Code [DDDDKB] 1610
Failure Code [DDDDKX] 1612
Failure Code [DDKAKA] 1613
Failure Code [DDKAKB] 1615
Failure Code [DDKBKA] 1617
Failure Code [DDKBKB] 1619
Failure Code [DDKCL4] 1620
Failure Code [DDKEL4] 1622
Failure Code [DDN7L4] 1624
Failure Code [DDN8L4] 1626
Failure Code [DDNLKA] 1628
Failure Code [DDNLKB] 1630
Failure Code [DDTSL1] 1632
Failure Code [DDTSLH] 1634
Failure Code [DFA4KX] 1636
Failure Code [DFA4KZ] 1637
Failure Code [DFA4L8] 1638
Failure Code [DFA5KA] 1639
Failure Code [DFA5KY] 1641
Failure Code [DFA6KA] 1643
Failure Code [DFA6KY] 1645
Failure Code [DFA7KX] 1647
Failure Code [DFA7KZ] 1648
Failure Code [DFA7L8] 1649
Failure Code [DFA8KA] 1650
Failure Code [DFA8KY] 1652
Failure Code [DFA9KA] 1654
Failure Code [DFA9KY] 1656
Failure Code [DFAAKX] 1658
Failure Code [DFAAKZ] 1659
Failure Code [DFAAL8] 1660
Failure Code [DFABKA] 1661
Failure Code [DFABKY] 1663
Failure Code [DFACKA] 1665
Failure Code [DFACKY] 1667
Failure Code [DGS1KA] 1669
Failure Code [DGS1KX] 1671
Failure Code [DGT1KA] 1673
Failure Code [DGT1KX] 1676
Failure Code [DH21KA] 1678
Failure Code [DH21KY] 1681
Failure Code [DHA4KA] 1683
Failure Code [DHAAMA] 1685
Failure Code [DHACMA] 1687
Failure Code [DHT5KA] 1689
Failure Code [DHT5KY] 1691
Failure Code [DHT7KA] 1693
Failure Code [DHT7KY] 1696
Failure Code [DK10KA] 1698
Failure Code [DK10KB] 1701
Failure Code [DK30KA] 1703
Failure Code [DK30KX] 1706
Failure Code [DK30KY] 1707
Failure Code [DK30KZ] 1709
Failure Code [DK30L8] 1710
Failure Code [DK31KA] 1711
Failure Code [DK31KY] 1714
Failure Code [DK40KA] 1716
Failure Code [DK40KY] 1719
Failure Code [DK55KX] 1721
Failure Code [DK55KZ] 1722
Failure Code [DK55L8] 1723
Failure Code [DK56KA] 1724
Failure Code [DK56KY] 1727
Failure Code [DK57KA] 1729
Failure Code [DK57KY] 1732
Failure Code [DKH1KA] 1734
Failure Code [DKH1KY] 1736
Failure Code [DLM3KA] 1738
Failure Code [DLM3MB] 1740
Failure Code [DLT3KA] 1741
Failure Code [DLT3KB] 1743
Failure Code [DR21KX] 1745
Failure Code [DR31KX] 1746
Failure Code [DV20KB] 1747
Failure Code [DW7BKA] 1749
Failure Code [DW7BKB] 1751
Failure Code [DWN1KA] 1752
Failure Code [DWN1KB] 1754
Failure Code [DWN1KY] 1756
Failure Code [DWN2KA] 1757
Failure Code [DWN2KB] 1759
Failure Code [DWN2KY] 1760
Failure Code [DWN3KA] 1761
Failure Code [DWN3KB] 1763
Failure Code [DWN3KY] 1765
Failure Code [DWN5KA] 1767
Failure Code [DWN5KB] 1769
Failure Code [DWN5KY] 1771
Failure Code [DXA2KA] 1773
Failure Code [DXA2KB] 1775
Failure Code [DXA2KY] 1777
Failure Code [DXH1KA] 1779
Failure Code [DXH1KB] 1781
Failure Code [DXH1KY] 1783
Failure Code [DXH4KA] 1785
Failure Code [DXH4KB] 1787
Failure Code [DXH4KY] 1789
Failure Code [DXH5KA] 1791
Failure Code [DXH5KB] 1793
Failure Code [DXH5KY] 1795
Failure Code [DXH6KA] 1797
Failure Code [DXH6KB] 1799
Failure Code [DXH6KY] 1800
Failure Code [DXH7KA] 1802
Failure Code [DXH7KB] 1804
Failure Code [DXH7KY] 1806
Failure Code [DXH8KA] 1808
Failure Code [DXH8KB] 1810
Failure Code [DXH8KY] 1812
Failure Code [DXHBKA] 1814
Failure Code [DXHBKB] 1816
Failure Code [DXHBKY] 1818
Failure Code [DXHCKA] 1820
Failure Code [DXHCKB] 1822
Failure Code [DXHCKY] 1824
Failure Code [DXHRKA] 1826
Failure Code [DXHRKB] 1828
Failure Code [DXHRKY] 1830
Failure Code [DXHSKA] 1831
Failure Code [DXHSKB] 1833
Failure Code [DXHSKY] 1835
Failure Code [DXHTKA] 1836
Failure Code [DXHTKB] 1837
Failure Code [DXHTKY] 1838
Failure Code [DXHUKA] 1839
Failure Code [DXHUKB] 1840
Failure Code [DXHUKY] 1841
Failure Code [DXHWKA] 1842
Failure Code [DXHWKB] 1843
Failure Code [DXHWKY] 1844
Failure Code [DXHXKA] 1845
Failure Code [DXHXKB] 1846
Failure Code [DXHXKY] 1847
Failure Code [DXHYKA] 1848
Failure Code [DXHYKB] 1849
Failure Code [DXHYKY] 1850
Failure Code [DXHZKA] 1851
Failure Code [DXHZKB] 1852
Failure Code [DXHZKY] 1853
Failure Code [DXJ4KA] 1854
Failure Code [DXJ4KB] 1855
Failure Code [DXJ8KA] 1856
Failure Code [DXJ8KB] 1857
Failure Code [DXJ8KY] 1858
Failure Code [DXJ9KA] 1859
Failure Code [DXJ9KB] 1860
Failure Code [DXJ9KY] 1861
Failure Code [DXJAKA] 1862
Failure Code [DXJAKB] 1863
Failure Code [DXJAKY] 1864
Failure Code [DXJBKA] 1865
Failure Code [DXJBKB] 1867
Failure Code [DXJBKY] 1869
Failure Code [F311KA] 1871
Failure Code [F311KB] 1873
Failure Code [F312KA] 1875
Failure Code [F312KB] 1877
Failure Code [F313KA] 1879
Failure Code [F313KB] 1880
Failure Code [F314KA] 1881
Failure Code [F314KB] 1883
Failure Code [F315KB] 1885
Failure Code [F315KY] 1887
Failure Code [F316KB] 1889
Failure Code [F316KY] 1891
Failure Code [F318KB] 1893
Failure Code [F318KY] 1894
Failure Code [F31AKB] 1895
Failure Code [F31AKY] 1897
Failure Code [F31BKB] 1899
Failure Code [F31BKY] 1901
Failure Code [F31CKB] 1903
Failure Code [F31CKY] 1905
Failure Code [F31DKB] 1907
Failure Code [F31DKY] 1909
Failure Code [F31EKB] 1911
Failure Code [F31EKY] 1913
Failure Code [F7FQKR] 1915
Failure Code [F7G0MC] 1918
Troubleshooting of Electrical System (E-Mode) 1919
E-1 Engine Does Not Start (Engine Does Not Crank) 1919
E-2 Manual Preheating System Does Not Operate 1926
E-3 Automatic Preheating System Does Not Operate 1929
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1931
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1933
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1937
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1939
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation 1940
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1942
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1943
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation 1944
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1945
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1946
E-14 Fuel Gauge Does Not Show Normally 1947
E-15 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 1949
E-16 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1950
E-17 Operation Mode Does Not Change 1951
E-18 Some Areas of Machine Monitor Screen are Not Shown 1952
E-19 Alarm Buzzer Does Not Operate or Does Not Stop 1953
E-20 Service Meter is Not Shown, While Starting Switch is in OFF Position 1954
E-21 Service Mode Cannot be Selected 1955
E-22 Horn Does Not Sound 1956
E-23 Horn Does Not Stop Sounding 1958
E-24 Backup Alarm Does Not Sound 1959
E-25 Backup Alarm Does Not Stop 1960
E-26 Headlamp Does Not Come On 1961
E-27 Rear Lamp Does Not Come On 1965
E-28 All Wipers Do Not Operate 1969
E-29 Front Wiper Does Not Operate 1974
E-30 Rear Wiper Does Not Operate 1978
E-31 Left Door Wiper Does Not Operate 1982
E-32 Right Door Wiper Does Not Operate 1986
E-33 Fuel Feed Pump Does Not Operate or Stop Automatically 1990
E-34 Fan Does Not Rotate in Reverse 1991
E-35 Gear Cannot be Shifted 1992
E-36 Front Washer Does Not Operate 1993
E-37 Rear Washer Does Not Operate 1996
E-38 Left Door Washer Does Not Operate 1999
E-39 Right Door Washer Does Not Operate 2002
E-40 Switch for Rear Work Equipment Does Not Operate 2005
E-41 KOMTRAX System Does Not Operate Correctly 2007
E-42 Pipelayer Attachment Does Not Operate 2008
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2009
Information Shown in Troubleshooting Table (H-Mode) 2009
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 2010
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2013
H-3 Machine Does Not Move Off at All Gear Speeds 2015
H-4 Machine Travels Only in One Direction, Forward or in Reverse 2018
H-5 Large Time Lag is in Gear Shifting or Directional Change 2019
H-6 Brake Does Not Work 2021
H-7 Power Train Oil Overheats 2022
H-8 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor 2024
H-9 Torque Converter Lockup Clutch Does Not Engage 2025
H-10 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) 2026
H-11 Steering Speed or Power is Not Sufficient 2028
H-12 All Work Equipment Operate Slowly 2030
H-13 All Work Equipment Do Not Operate 2032
H-14 Pipelayer Attachment Speed or Power is Low 2034
H-15 Counterweight Speed or Power is Low 2036
H-16 Rear Attachment Speed or Power is Low 2038
H-17 Hydraulic Drift of Pipelayer Attachment is Large 2040
H-18 Hydraulic Drift of Counterweight is Large 2041
H-19 Switch for Rear Work Equipment Does Not Operate 2042
H-20 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2043
H-21 Unusual Noise is Heard from Around Fan 2044
Troubleshooting of Engine (S-Mode) 2045
Information Shown in Troubleshooting Table (S-Mode) 2045
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2046
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2047
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2048
S-4 Engine Startability is Unsatisfactory 2049
S-5 Engine Does Not Pick Up Smoothly 2051
S-6 Engine Stops During Operation 2053
S-7 Engine Runs Rough or is Not Stable 2055
S-8 Engine Lacks Power 2056
S-9 KDPF Becomes Clogged in a Short Time 2058
S-10 Engine Oil Consumption is Excessive 2060
S-11 Oil Becomes Dirty Quickly 2061
S-12 Fuel Consumption is Excessive 2062
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2063
S-14 Oil Pressure Drops 2064
S-15 Fuel Mixes Into Engine Oil 2066
S-16 Water Mixes Into Engine Oil (Milky) 2067
S-17 Coolant Temperature Increases Too High (Overheating) 2068
S-18 Unusual Noise is Heard 2069
S-19 Vibration is Excessive 2070
S-20 Air Cannot be Bled from Fuel Circuit 2071
S-21 Active Regeneration is Done Frequently 2072
S-22 Active Regeneration Continues Long 2074
S-23 White Smoke is Exhausted During Active Regeneration 2075
S-24 DEF Consumption is Excessive 2076
S-25 There is Unusual Smell (Irritating Odor) 2078
S-26 Foreign Materials Enter DEF (DEF Increases) 2079
50 Disassembly and Assembly 2081
Table of Contents 2082
Precautions Before Work 2087
Related Information on Disassembly and Assembly 2088
How to Read This Manual 2088
Coating Materials List 2089
Special Tool List 2094
Sketches of Special Tools 2115
Engine and Cooling System 2135
Remove and Install Supply Pump Assembly 2135
How to Remove Supply Pump Assembly 2136
How to Install Supply Pump Assembly 2144
Remove and Install Injector Assembly 2154
How to Remove Injector Assembly 2155
How to Install Injector Assembly 2164
Remove and Install Fuel Doser Assembly 2177
How to Remove Fuel Doser Assembly 2177
How to Install Fuel Doser Assembly 2178
Remove and Install Cylinder Head Assembly 2179
How to Remove Cylinder Head Assembly 2181
How to Install Cylinder Head Assembly 2194
Remove and Install EGR Valve Assembly 2216
How to Remove EGR Valve Assembly 2217
How to Install EGR Valve Assembly 2218
Remove and Install EGR Cooler Assembly 2220
How to Remove EGR Cooler Assembly 2221
How to Install EGR Cooler Assembly 2224
Remove and Install Starter Assembly 2227
How to Remove Starting Motor Assembly 2227
How to Install Starting Motor Assembly 2229
Remove and Install Alternator Belt 2232
How to Remove Alternator Belt 2232
How to Install Alternator Belt 2234
Remove and Install Radiator Assembly 2236
How to Remove Radiator Assembly 2237
How to Install Radiator Assembly 2242
Remove and Install Hydraulic Oil Cooler Assembly 2250
How to Remove Hydraulic Oil Cooler Assembly 2251
How to Install Hydraulic Oil Cooler Assembly 2253
Remove and Install Aftercooler Assembly 2256
How to Remove Aftercooler Assembly 2256
How to Install Aftercooler Assembly 2258
Remove and Install Cooling Fan Drive Assembly 2261
How to Remove Cooling Fan Drive Assembly 2262
How to Install Cooling Fan Drive Assembly 2264
Remove and Install Cooling Fan Motor Assembly 2267
How to Remove Cooling Fan Motor Assembly 2268
How to Install Cooling Fan Motor Assembly 2269
Remove and Install Engine Assembly 2270
How to Remove Engine Assembly 2272
How to Install Engine Assembly 2282
Remove and Install Engine Front Oil Seal 2292
How to Remove Engine Front Oil Seal 2293
How to Install Engine Front Oil Seal 2294
Remove and Install Engine Rear Oil Seal 2298
How to Remove Engine Rear Oil Seal 2299
How to Install Engine Rear Oil Seal 2300
Remove and Install Engine Hood Assembly 2304
How to Remove Engine Hood Assembly 2304
How to Install Engine Hood Assembly 2308
Remove and Install Fuel Tank Assembly 2313
How to Remove Fuel Tank Assembly 2314
How to Install Fuel Tank Assembly 2322
Remove and Install DEF Tank Assembly 2331
How to Remove DEF Tank Assembly 2332
How to Install DEF Tank Assembly 2342
Remove and Install DEF Tank Sensor Flange Assembly 2350
How to Remove DEF Tank Sensor Flange Assembly 2351
How to Install DEF Tank Sensor Flange Assembly 2361
Remove and Install DEF Tank Sensor 2370
How to Remove DEF Tank Sensor 2370
How to Install DEF Tank Sensor 2370
Remove and Install DEF Tank Strainer 2377
How to Remove DEF Tank Strainer 2377
How to Install DEF Tank Strainer 2377
Remove and Install DEF Tank Filler Port Filter 2378
How to Remove DEF Tank Filler Port Filter 2378
How to Install DEF Tank Filler Port Filter 2379
Remove and Install KDPF Assembly 2382
How to Remove KDPF Assembly 2382
How to Install KDPF Assembly 2387
Disassemble and Assemble KDPF Assembly 2393
How to Disassemble KDPF Assembly 2393
How to Assemble KDPF Assembly 2397
Remove and Install SCR Assembly 2402
How to Remove SCR Assembly 2403
How to Install SCR Assembly 2406
Remove and Install KDPF and SCR Assembly 2411
How to Remove KDPF and SCR Assembly 2412
How to Install KDPF and SCR Assembly 2418
Remove and Install KCCV Assembly 2424
How to Remove KCCV Assembly 2424
How to Install KCCV Assembly 2427
Remove and Install DEF Mixing Tube 2430
How to Remove DEF Mixing Tube 2431
How to Install DEF Mixing Tube 2435
Remove and Install DEF Injector 2442
How to Remove DEF Injector 2443
How to Install DEF Injector 2446
Remove and Install DEF Pump 2450
How to Remove DEF Pump 2450
How to Install DEF Pump 2457
Remove and Install DEF Hose 2464
How to Remove DEF Hose 2464
How to Install DEF Hose 2475
Remove and Install Air Cleaner Assembly 2488
How to Remove Air Cleaner Assembly 2488
How to Install Air Cleaner Assembly 2489
Remove and Install Air Conditioner Compressor Assembly 2491
How to Remove Air Conditioner Compressor Assembly 2491
How to Install Air Conditioner Compressor Assembly 2492
Remove and Install Air Conditioner Condenser Assembly 2494
How to Remove Air Conditioner Condenser Assembly 2494
How to Install Air Conditioner Condenser Assembly 2496
Power Train 2499
Remove and Install Damper Assembly 2499
How to Remove Damper Assembly 2499
How to Install Damper Assembly 2501
Disassemble and Assemble Damper Assembly 2504
How to Disassemble Damper Assembly 2504
How to Assemble Damper Assembly 2506
Remove and Install Power Train Unit Assembly 2509
How to Remove Power Train Unit Assembly 2510
How to Install Power Train Unit Assembly 2517
Disconnect and Connect Power Train Unit Assembly 2524
How to Disconnect Power Train Unit Assembly 2525
How to Connect Power Train Unit Assembly 2533
Disassemble and Assemble PTO Assembly 2541
How to Disassemble PTO Assembly 2541
How to Assemble PTO Assembly 2545
Disassemble and Assemble Torque Converter Assembly 2550
How to Disassemble Torque Converter Assembly 2550
How to Assemble Torque Converter Assembly 2556
Disassemble and Assemble Transmission Assembly 2563
How to Disassemble Transmission Assembly 2563
How to Assemble Transmission Assembly 2573
Disassemble and Assemble HSS Assembly 2585
How to Disassemble HSS Assembly 2586
How to Assemble HSS Assembly 2595
Remove and Install HSS Motor Assembly 2609
How to Remove HSS Motor Assembly 2609
How to Install HSS Motor Assembly 2611
Remove and Install Final Drive Assembly 2612
How to Remove Final Drive Assembly 2612
How to Install Final Drive Assembly 2615
Disassemble and Assemble Final Drive Assembly 2617
How to Disassemble Final Drive Assembly 2618
How to Assemble Final Drive Assembly 2624
Undercarriage and Frame 2635
Remove and Install Track Frame Assembly 2635
How to Remove Track Frame Assembly 2636
How to Install Track Frame Assembly 2643
Remove and Install Idler Assembly 2651
How to Remove Idler Assembly 2651
How to Install Idler Assembly 2652
Disassemble and Assemble Idler Assembly 2654
How to Disassemble Idler Assembly 2654
How to Assemble Idler Assembly 2656
Remove and Install Recoil Spring Assembly 2659
How to Remove Recoil Spring Assembly 2659
How to Install Recoil Spring Assembly 2660
Disassemble and Assemble Recoil Spring Assembly 2661
How to Disassemble Recoil Spring Assembly 2662
How to Assemble Recoil Spring Assembly 2666
Remove and Install Track Roller Assembly 2671
How to Remove Track Roller Assembly 2671
How to Install Track Roller Assembly 2672
Disassemble and Assemble Track Roller Assembly 2674
How to Disassemble Track Roller Assembly 2674
How to Assemble Track Roller Assembly 2676
Remove and Install Carrier Roller Assembly 2679
How to Remove Carrier Roller Assembly 2679
How to Install Carrier Roller Assembly 2680
Disassemble and Assemble Carrier Roller Assembly 2682
How to Disassemble Carrier Roller Assembly 2683
How to Assemble Carrier Roller Assembly 2685
Remove and Install Pivot Shaft Assembly 2688
How to Remove Pivot Shaft Assembly 2688
How to Install Pivot Shaft Assembly 2690
Separate and Connect Track Assembly 2693
How to Examine Before Separation of Track Assembly 2693
How to Separate Track Assembly (Standard) 2693
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2694
How to Install Track Assembly 2695
Disassemble and Assemble Track Assembly Generally 2697
How to Disassemble Full Track Shoe Assembly 2698
How to Assemble Full Track Shoe Assembly 2700
Disassemble and Assemble One Track Link Assembly in Field 2712
How to Disassemble One Track Link Assembly in Field 2713
How to Assemble One Track Link Assembly in Field 2714
Disassemble and Assemble Master Link 2716
How to Disassemble Master Link 2716
How to Assemble Master Link 2717
Remove and Install Cross Bar Assembly 2720
How to Remove Cross Bar Assembly 2720
How to Install Cross Bar Assembly 2721
Remove and Install Sprocket 2723
How to Remove Sprocket 2723
How to Install Sprocket 2723
Remove and Install Center Under Guard Assembly 2725
How to Remove Underguard Assembly 2725
How to Install Underguard Assembly 2734
Hydraulic System 2744
Remove and Install Hydraulic Tank Assembly 2744
How to Remove Hydraulic Tank Assembly 2745
How to Install Hydraulic Tank Assembly 2747
Remove and Install Work Equipment Pump and HSS Pump Assembly 2749
How to Remove Work Equipment Pump and HSS Pump Assembly 2750
How to Install Work Equipment Pump and HSS Pump Assembly 2754
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2759
How to Remove Power Train Pump and Steering Lubrication Pump Assembly 2760
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2765
Remove and Install Cooling Fan Pump Assembly 2769
How to Remove Cooling Fan Pump Assembly 2770
How to Install Cooling Fan Pump Assembly 2773
Remove and Install Scavenging Pump Assembly 2776
How to Remove Scavenging Pump Assembly 2776
How to Install Scavenging Pump Assembly 2777
Remove and Install Control Valve Assembly 2779
How to Remove Control Valve Assembly 2780
How to Install Control Valve Assembly 2782
CAB Related Parts 2785
Remove and Install Operator Cab Assembly 2785
How to Remove Operator Cab Assembly 2787
How to Install Operator Cab Assembly 2792
Remove and Install Operator Cab Glass (Adhered Glass) 2799
How to Remove Operator Cab Glass (Adhered Glass) 2801
How to Install Operator Cab Glass (Adhered Glass) 2801
Remove and Install Air Conditioner Unit Assembly 2806
How to Remove Air Conditioner Unit Assembly 2807
How to Install Air Conditioner Unit Assembly 2816
Remove and Install Operator Seat 2825
How to Remove Operator Seat 2825
How to Install Operator Seat 2827
How to Remove and Install Seat Belt 2829
How to Remove Seat Belt 2829
How to Install Seatbelt 2830
Electrical System 2831
Remove and Install Engine Controller Assembly 2831
How to Remove Engine Controller Assembly 2832
How to Install Engine Controller Assembly 2835
Remove and Install Power Train Controller Assembly 2840
How to Remove Power Train Controller Assembly 2840
How to Install Power Train Controller Assembly 2841
Remove and Install Work Equipment Controller Assembly 2843
How to Remove Work Equipment Controller Assembly 2843
How to Install Work Equipment Controller Assembly 2844
Remove and Install Machine Monitor Assembly 2846
How to Remove Machine Monitor Assembly 2846
How to Install Machine Monitor Assembly 2847
Remove and Install Mass Air Flow and Temperature Sensor 2849
How to Remove Mass Air Flow and Temperature Sensor 2849
How to Install Mass Air Flow and Temperature Sensor 2851
Remove and Install KCCV Crankcase Pressure Sensor 2852
How to Remove KCCV Crankcase Pressure Sensor 2852
How to Install KCCV Crankcase Pressure Sensor 2853
Remove and Install SCR Temperature Sensor 2854
How to Remove SCR Temperature Sensor 2854
How to Install SCR Temperature Sensor 2856
Remove and Install Battery Relay 2858
How to Remove Battery Relay 2858
How to Install Battery Relay 2864
Remove and Install Gateway Controller Assembly 2871
How to Remove Gateway Controller Assembly 2871
How to Install Gateway Controller Assembly 2875
Remove and Install Communication Terminal 2880
How to Remove Communication Terminal 2880
How to Install Communication Terminal 2886
Remove and Install Communication Terminal Wiring Harness 2892
How to Remove Communication Terminal Wiring Harness 2893
How to Install Communication Terminal Wiring Harness 2906
60 Maintenance Standard 2919
Table of Contents 2920
Explanation of Terms for Maintenance Standard 2921
Engine and Cooling System 2923
Maintenance Standard for Engine Mount 2923
Maintenance Standard for Damper 2925
Maintenance Standard for Cooling System 2927
Maintenance Standard for Cooling Fan Pump 2929
Maintenance Standard for Servo Valve 2932
Maintenance Standard for Cooling Fan Motor 2934
Power Train 2936
Maintenance Standard for Universal Joint 2936
Maintenance Standard for Power Train Mount 2937
Maintenance Standard for Torque Converter and PTO 2939
Maintenance Standard for Torque Converter Control Valve 2946
Maintenance Standard for ECMV (Lockup Clutch Valve) 2947
Maintenance Standard for ECMV (Stator Clutch Valve) 2948
Maintenance Standard for Transmission 2949
Maintenance Standard for ECMV (Transmission) 2954
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 2956
Maintenance Standard for Transmission Lubrication Relief Valve 2957
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake 2958
Maintenance Standard for Brake Control Valve 2965
Maintenance Standard for ECMV (Brake) 2968
Maintenance Standard for Solenoid Valve (Brake) 2969
Maintenance Standard for Sudden Stop Prevention Valve 2970
Maintenance Standard for Final Drive 2971
Maintenance Standard for Sprocket 2974
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2975
Undercarriage and Frame 2976
Maintenance Standard for Main Frame 2976
Maintenance Standard for Suspension 2977
Maintenance Standard for Track Frame and Idler Cushion 2980
Maintenance Standard for Idler 2982
Maintenance Standard for Track Roller 2984
Maintenance Standard for Carrier Roller 2986
Maintenance Standard for Track Shoes 2988
Maintenance Standard for Single Shoes 2990
Hydraulic System 2991
Maintenance Standard for Hydraulic Tank 2991
Maintenance Standard for Single Pump (Scavenging) 2992
Maintenance Standard for Duplex Pump (Lubrication, Power Train) 2993
Maintenance Standard for Work Equipment and HSS Pump 2995
Maintenance Standard for PC-EPC Valve 2997
Maintenance Standard for HSS Motor 2998
Maintenance Standard for Control Valve 3000
Maintenance Standard for Self-Pressure Reducing Valve 3012
CAB Related Parts 3015
Maintenance Standard for CAB Mount 3015
80 Appendix 3017
Table of Contents 3018
Precautions Before Work 3020
Air Conditioner System 3021
Precautions for Refrigerant 3021
Air Conditioner Component 3022
Specifications of Air Conditioner 3024
Structure and Function of Refrigeration Cycle 3025
Outline of Refrigeration Cycle 3026
Component Parts of Air Conditioner System 3028
Air Conditioner Unit 3028
Configuration Diagram of Air Conditioner Unit 3028
Function of Air Conditioner Unit 3030
Component Parts of Air Conditioner Unit 3032
Function of Evaporator as Air Conditioner Unit Component 3033
Function of Heater Core as Air Conditioner Unit Component 3033
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3033
Function of Servo Motor as Air Conditioner Unit Component 3033
Structure of Expansion Valve as Air Conditioner Unit Component 3034
Function of Expansion Valve as Air Conditioner Unit Component 3034
Operate Expansion Valve as Air Conditioner Unit Component 3034
Function of Triple Pressure Switch 3035
Air Conditioner Controller 3036
Structure of Air Conditioner Controller 3036
Compressor 3037
Structure of Compressor 3037
Specifications of Compressor 3037
Function of Compressor 3037
Condenser 3038
Structure of Condenser 3038
Specifications of Condenser 3038
Function of Condenser 3038
Receiver Drier 3039
Structure of Receiver Dryer 3039
Specifications of Receiver Dryer 3039
Function of Receiver Dryer 3039
Air Conditioner Related Sensors 3040
Structure of Sunlight Sensor 3040
Function of Sunlight Sensor 3040
Structure of Outside Temperature Sensor 3040
Function of Outside Air Temperature Sensor 3040
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3042
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3044
System Diagram of Air Conditioner 3046
Input and Output Signals of Air Conditioner Controller 3047
Function of Air Conditioner Controller 3048
Locations of Air Conditioner Parts and Layout of Connectors 3049
Examine Air Leakage (Duct) 3057
How to Examine Air Leakage (Duct) 3057
Examine Air Conditioner with Self-Diagnosis Function 3060
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3061
Examine Vent (Mode) Changeover 3062
How to Examine Vent (Mode) Changeover 3062
Examine Fresh/Recirc Air Changeover 3063
How to Examine Fresh/Recirc Air Changeover 3063
Examine Sunlight Sensor 3064
How to Examine Sunlight Sensor 3064
Examine Refrigerant (Triple) Pressure Switch 3065
How to Examine Refrigerant (Triple) Pressure Switch 3065
Examine Relay 3066
How to Examine Relay 3066
Air Conditioner Troubleshooting Chart 1 3067
Air Conditioner Troubleshooting Chart 2 3068
Information Shown in Troubleshooting Table 3071
Failure Code [879AKA] 3072
Failure Code [879AKB] 3073
Failure Code [879BKA] 3074
Failure Code [879BKB] 3076
Failure Code [879CKA] 3078
Failure Code [879CKB] 3079
Failure Code [879DKZ] 3080
Failure Code [879EMC] 3082
Failure Code [879FMC] 3083
Failure Code [879GKX] 3084
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3086
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3088
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3092
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3094
Troubleshooting by Gauge Pressure 3096
Connect Service Tool 3099
How to Connect Service Tool 3099
Precautions for Disconnection and Connection of Air Conditioner Piping 3101
Handle Compressor Oil 3103
90 Circuit Diagrams 3105
Table of Contents 3106
How to Read the Codes for Electric Cable 3107
Hydraulic Circuit Diagram 3111
Symbols Used in Hydraulic Circuit Diagram 3111
Hydraulic Circuit Diagram (1/3) 3115
Hydraulic Circuit Diagram (2/3) 3117
Hydraulic Circuit Diagram (3/3) 3119
Power Train Hydraulic Circuit Diagram 3121
Electrical Circuit Diagram 3123
Symbols Used in Electric Circuit Diagram 3123
Electrical Circuit Diagram(1/16) 3127
Electrical Circuit Diagram(2/16) 3129
Electrical Circuit Diagram(3/16) 3131
Electrical Circuit Diagram(4/16) 3133
Electrical Circuit Diagram(5/16) 3135
Electrical Circuit Diagram(6/16) 3137
Electrical Circuit Diagram(7/16) 3139
Electrical Circuit Diagram(8/16) 3141
Electrical Circuit Diagram(9/16) 3143
Electrical Circuit Diagram(10/16) 3145
Electrical Circuit Diagram(11/16) 3147
Electrical Circuit Diagram(12/16) 3149
Electrical Circuit Diagram(13/16) 3151
Electrical Circuit Diagram(14/16) 3153
Electrical Circuit Diagram(15/16) 3155
Electrical Circuit Diagram(16/16) 3157
Index 3159

S.V  21/12/24