Komatsu D61EXi-24 D61PXi-24 Bulldozer Shop Manual SEN06578-10 PDF

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Komatsu D61EXi-24 D61PXi-24 Bulldozer Shop Manual SEN06578-10 – PDF DOWNLOAD

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Komatsu D61EXi-24 D61PXi-24 Bulldozer Shop Manual SEN06578-10 – PDF DOWNLOAD 

Language : English
Pages : 3178
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu D61EXi-24 D61PXi-24 Bulldozer Shop Manual SEN06578-10 – PDF DOWNLOAD

SERIAL NUMBERS

D61EXi-40001 and up
D61PXi-40001 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 D61PXi-24 Bulldozer Shop Manual SEN06578-10 – PDF DOWNLOAD

SERIAL NUMBERS

D61EXi-40001 and up
D61PXi-40001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 23
Foreword, Safety, Basic Information 29
How to Read the Shop Manual 29
Safety Notice for Operation 31
Precautions to Prevent Fire 39
Procedures If Fire Occurs 41
Precautions When You Discard Waste Materials 42
Procedures for Exhaust Gas Regulations 43
Precautions for DEF 44
General Character and Precautions for Handling 44
Precautions When You Add 44
Precautions for Storage 44
Precautions for Fire Hazard and Leakage 44
Other Precautions 44
Store DEF 45
Precautions When You Handle Hydraulic Equipment 46
Precautions When You Disconnect and Connect Pipings 49
Precautions When You Handle Electrical Equipment 56
Precautions When You Handle Fuel System Equipment 58
Precautions When You Handle Intake System Equipment 59
Practical Use of KOMTRAX 60
Disconnect and Connect Push-Pull Type Coupler 61
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 61
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 62
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 63
Precautions for Disconnection and Connection of Connectors 65
Disconnect and Connect Deutsch Connector 69
How to Disconnect and Connect Slide Lock Type Connector 70
Disconnect and Connect Connector with Lock to Pull 72
Disconnect and Connect Connector with Lock to Push 73
Disconnect and Connect Connector with Housing to Rotate 75
How to Read the Codes for Electric Cable 76
Explanation of Terms for Maintenance Standard 80
Standard Tightening Torque Table 83
Conversion Table 90
01 Specification 95
Table of Contents 96
Abbreviation List 97
Specifications 103
Specification Drawing 103
Specification Drawing: D61EXI-24 103
Specification Drawing: D61PXI-24 105
Specifications 107
Specifications: D61EXI-24 107
Specifications: D61PXI-24 113
Weight Table 118
Weight Table: D61EXI-24 118
Weight Table: D61PXI-24 120
Table of Fuel, Coolant, and Lubricants 122
10 Structure and Function 123
Table of Contents 124
Abbreviation List 128
Urea SCR System 134
Layout Drawing of Urea SCR System 134
Urea SCR System Diagram 137
Function of Urea SCR System 138
Function of DEF System 138
Inducement Strategy 140
Component Parts of Urea SCR System 154
DEF Mixing Tube 154
SCR Assembly 155
DEF Tank 157
DEF Pump 159
DEF Injector 160
DEF Hose 161
DEF Tank Heating Valve 162
Boot-up System 163
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 163
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 164
System Operating Lamp System 165
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 165
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 165
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 165
Function of System Operating Lamp System (Machine with Gateway Function Controller) 166
Battery Disconnect Switch 168
Layout Drawing of Battery Disconnect Switch 168
Function of Battery Disconnect Switch 168
Engine System 170
Layout Drawing of Engine System 170
Engine Control System 172
Layout of Engine Control System (Machine with KOMTRAX Terminal) 172
Layout of Engine Control System (Machine with Gateway Function Controller) 174
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 176
System Diagram of Engine Control System (Machine with Gateway Function Controller) 178
Function of Engine Control System (Machine with KOMTRAX Terminal) 180
Function of Engine Control System (Machine with Gateway Function Controller) 182
Automatic Idle Stop System 184
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 184
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 185
Function of Automatic Idle Stop System 185
Component Parts of Engine System 188
Damper 188
VGT 189
EGR System 193
EGR Valve 195
EGR Cooler 197
KCCV System 199
KCCV Ventilator 201
KDPF 203
Cooling System 207
Layout Drawing of Cooling System 207
Specifications of Cooling System 208
Cooling Fan Control System 209
System Diagram of Cooling Fan Control System 209
Function of Cooling Fan Control System 210
Component Parts of Cooling System 212
Cooling Fan Motor 212
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 217
Hydraulic Oil Cooler Bypass Valve 219
HST Charge Safety Valve 220
Control System 222
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 222
Layout Drawing of Control System (Machine with Gateway Function Controller) 223
Machine Monitor System 224
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 224
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 225
Function of Machine Monitor System 225
KOMTRAX System 226
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 226
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 226
Function of KOMTRAX System 227
Component Parts of Control System 228
Machine Monitor 228
KOMTRAX Terminal 243
Gateway Function Controller 245
Communication Terminal 248
HST Controller 250
Engine Controller 254
Fuel Control Dial 260
Decelerator and Brake Potentiometer 262
Hydraulic System 264
Layout Drawing of Hydraulic System 264
CLSS 265
Structure of CLSS 265
Function of CLSS 266
Component Parts of Hydraulic System 268
Hydraulic Tank 268
Work Equipment and Cooling Fan Pump 270
LS Valve 278
PC Valve 279
Control Valve 282
Power Train System 303
Layout Drawing of HST System 303
Operation of HST System 304
Steering and Brake Control System 306
Layout Drawing of Steering and Brake Control System 306
Function of Steering and Brake Control System 306
HST Control System 308
System Diagram of HST Control System 308
Gear Shift Control Function 309
Engine Low Speed Matching Control Function 313
HST Pump and Motor Sequence Control Function 313
Deceleration and Brake Control Function 315
Gear Shift Control Function by Load 316
Turn Control Function 316
Straight Travel Correction Control Function 317
Parking Brake Control System 319
System Diagram of Parking Brake Control System 319
Function of Parking Brake Control System 320
Operation of Parking Brake Control System 321
Component Parts of Power Train System 322
HST Pump 322
HST Charge Pump 338
HST Motor 339
Final Drive 351
Electric Steering Electric Lever 355
Work Equipment System 358
Work Equipment Control 358
Layout Drawing of Work Equipment Control 358
Function of Work Equipment Control 359
Layout Drawing of Front Work Equipment 361
Layout Drawing of Fixed Multi-Shank Ripper 362
Component Parts of Work Equipment System 363
Ripper PPC Valve 363
5-Spool EPC and Solenoid Valve 367
Pilot Circuit Accumulator 373
Angle Control EPC Valve 374
Quick Drop Valve 377
Piston Valve 379
Electric Blade Control Lever 380
ICT System 382
Layout Drawing of ICT System 382
System Diagram of ICT Control System 384
Blade Control System 386
Function of Blade Control System 386
Leveling Mode System Diagram 388
Function of Leveling Mode 389
Operation of Leveling Mode 389
Dozing Mode System Diagram 390
Function of Dozing Mode 390
Operation of Dozing Mode 390
Smooth Start System 392
Smooth Start System Diagram 392
Function of Smooth Start System 392
Operation of Smooth Start System 392
Slip Control System 394
Slip Control System Diagram 394
Function of Slip Control System 394
Operation of Slip Control System 394
Assist Control System 395
Assist Control System Diagram 395
Function of Assist Control System 395
Operation of Assist Control System 396
HST Speed Range Control System 397
HST Speed Range Control System Diagram 397
Function of HST Speed Range Control System 397
Operation of HST Speed Range Control System 397
Component Parts of ICT System 399
ICT Sensor Controller 399
Control Box 403
GNSS Receiver 406
GNSS Antenna 410
IMU Sensor 411
Stroke and Reset Sensor for Blade Lift Cylinder 415
Stroke Sensor for Blade Tilt Cylinder 418
Stroke Sensor for Blade Angle Cylinder 420
Undercarriage and Frame 422
Main Frame 422
Structure of Main Frame 422
Suspension 423
Structure of Suspension 423
Specifications of Suspension 424
Function of Suspension 425
Track Frame and Idler Cushion 426
Structure of Track Frame and Idler Cushion 426
Function of Track Frame and Idler Cushion 428
Work Equipment 429
Structure of Front Work Equipment 429
Structure of Fixed Multi-Shank Ripper 430
CAB Related Parts 431
ROPS CAB 431
Structure of ROPS CAB (Machine with KOMTRAX Terminal) 431
Structure of ROPS CAB (Machine with Gateway Function Controller) 432
Function of ROPS CAB 433
CAB Mount 434
Structure of CAB Mount 434
Function of CAB Mount 434
20 Standard Value Table 435
Table of Contents 436
Abbreviation List 437
Standard Value Table for Engine 443
Standard Value Table for Engine: D61EXI-24 443
Standard Value Table for Engine: D61PXI-24 447
Standard Value Table for Machine 451
Standard Value Table for Machine: D61EXI-24 451
Standard Value Table for Machine: D61PXI-24 468
Machine Posture and Procedures to Measure Performance 485
30 Testing and Adjusting 487
Table of Contents 488
Precautions Before Work 492
Abbreviation List 493
Related Information on Testing and Adjusting 499
Tools for Testing and Adjusting 499
Sketch of Tools for Testing and Adjusting 507
Engine and Cooling System 512
Examine Engine Speed 512
How to Examine Engine Speed 512
Examine Boost Pressure 515
How to Examine Boost Pressure 515
Examine Exhaust Gas Color 517
How to Examine Exhaust Gas Color with the Handy Smoke Checker 517
How to Examine Exhaust Gas Color with Smoke Meter 519
Examine Mass Air Flow and Temperature Sensor 521
How to Examine Mass Air Flow and Temperature Sensor 521
Examine and Adjust Valve Clearance 523
Check Valve Clearance 523
Adjust Valve Clearance 524
Examine Compression Pressure 525
How to Examine Compression Pressure 525
Examine Blowby Pressure 530
How to Examine Blowby Pressure 530
Examine Engine Oil Pressure 533
How to Examine Engine Oil Pressure 533
Examine EGR Valve and VGT Oil Pressure 534
How to Examine EGR Valve and VGT Oil Pressure 534
Examine Fuel Pressure 536
How to Examine Fuel Pressure 537
Examine Fuel Discharge, Return and Leakage 542
How to Examine Fuel Discharge, Return, and Leakage 543
Bleed Air from Fuel System 549
How to Bleed Air from Fuel System 549
Examine Fuel Circuit for Leakage 550
How to Examine Fuel System for Leakage 550
Handle Cylinder Cut-out Mode Operation 552
Handle No-Injection Cranking Operation 553
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 554
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 554
Examine Installed Condition of Cylinder Heads and Manifolds 555
How to Examine Installed Condition of Cylinder Heads and Manifolds 555
Examine Engine Piping for Damage and Looseness 556
How to Examine Engine Piping for Damage and Looseness 556
Examine Alternator Belt 557
How to Examine Alternator Belt 557
Examine Automatic Tensioner 559
How to Examine Automatic Tensioner 559
Write Correction for Ash in Soot Accumulation to Engine Controller 561
How to Write Correction for Ash in Soot Accumulation to Engine Controller 561
Examine SCR Related Functions 562
Examine DEF Pump Raised Pressure 566
Examine Injection Volume from DEF Injector 569
Examine DEF Line Heater Relay 1 574
Examine DEF Line Heater Relay 2 577
Examine DEF Pump Heater Relay 580
Examine DEF Tank Heater Valve 584
Examine SCR Denitration Efficiency 588
Clean DEF Tank 591
How to Clean DEF Tank 591
Clean DEF Tank Mounting Part 595
How to Clean DEF Tank Mounting Part 595
Clean DEF Pump 596
How to Clean DEF Pump 596
Power Train 602
Examine and Adjust HST Oil Pressure 602
Examine HST Oil Pressure 602
Adjust HST Oil Pressure 605
Bleed Air from HST Pump 607
How to Bleed Air from HST Pump 607
Examine Outlet Pressure of Solenoid Valve 608
How to Examine Outlet Pressure of Solenoid Valve 608
Examine Travel Deviation 613
How to Examine Travel Deviation 613
Examine Brake Performance Simply 615
How to Examine Brake Performance Simply 615
Examine and Adjust Deceleration/Brake Pedal 616
How to Examine Deceleration/Brake Pedal 616
How to Adjust Deceleration/Brake Pedal 618
Adjust Parking Brake Lever 620
How to Adjust Parking Brake Lever 620
Move Machine When It Cannot Travel 622
Move Machine with Hydraulic Type Parking Brake Release System 622
Move Machine After You Remove Final Drive Shaft 624
Undercarriage and Frame 626
Examine and Adjust Idler Clearance 626
How to Examine and Adjust Idler Clearance 626
Examine Sprocket Wear 627
How to Examine Sprocket Wear 627
Examine and Adjust Track Tension 628
How to Examine Track Tension 628
How to Adjust Track Tension 628
Hydraulic System 630
Release Remained Pressure in Hydraulic Circuit 630
How to Release Remained Pressure in Hydraulic System 630
Examine and Adjust Work Equipment Circuit Oil Pressure 631
How to Examine Work Equipment Circuit Oil Pressure 631
Adjust Work Equipment Circuit Oil Pressure 632
Examine and Adjust Oil Pressure in Control Circuit 634
Examine Oil Pressure in Control Circuit 634
Adjust Oil Pressure in Control Circuit 635
Examine Outlet Pressure of EPC Solenoid Valve 636
How to Examine Outlet Pressure of EPC Solenoid Valve 636
Bleed Air from Work Equipment and Cooling Fan Pump 638
How to Bleed Air from Work Equipment and Cooling Fan Pump 638
Examine Cooling Fan Speed 639
How to Examine Cooling Fan Speed 639
Examine Cooling Fan Circuit Oil Pressure 640
How to Examine Cooling Fan Circuit Oil Pressure 640
Examine Parts Which Cause Hydraulic Drift of Work Equipment 642
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 642
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 642
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 643
Examine Oil Leakage from Work Equipment Cylinder 644
How to Examine Internal Oil Leakage of Work Equipment Cylinder 644
Bleed Air from Work Equipment Cylinders 646
Bleed Air from Work Equipment Cylinder 646
Work Equipment 647
Adjust Work Equipment Lock Lever 647
How to Adjust Work Equipment Lock Lever 647
Examine and Adjust Play of Blade Electric Lever 649
How to Examine Play of Blade Electric Lever 651
Adjust Play of Blade Electric Lever 651
Replace Universal Joint 652
Electrical System 659
Set and Operate Machine Monitor 659
Operator Mode 663
Function to Show Technician Identification Status Screen 663
Function to Show Operator Identification Input Screen 663
Examine Function by LCD (Liquid Crystal Display) 664
Examine Function of Service Meter 664
Usage Limitation and Change Maintenance Password 664
Service Mode 667
How to Operate Service Mode 667
How to See Pre-defined Monitoring Information 669
How to Examine Self-Define Monitor Information 675
Abnormality Record Menu 687
How to See Maintenance Record 691
Maintenance Mode Setting 692
Set Phone Number Entry 696
Default Menu 698
Diagnostic Tests Menu 705
Adjustment Menu 714
No-Injection Cranking Operation 782
KOMTRAX Settings Menu 785
Show Service Message 789
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 791
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 796
Start Up KOMTRAX System (Machine with Gateway Function Controller) 798
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 804
Adjust After Replacement of HST Controller 806
How to Adjust After Replacement of HST Controller 806
Adjust After Replacement of Electric and Hydraulic Equipment 812
Adjust Rearview Camera Angle 814
How to Adjust Rearview Camera Angle 814
Handle Voltage Circuit of Engine Controller 815
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 816
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 817
Examine Diodes 818
Examine Diodes by Digital Tester 818
How to Examine Diodes by Analog Tester 818
ICT System 819
Set and Operate Control Box 819
Examine and Adjust ICT Related Devices 820
Calibrate Blade Edge Position 823
How to Operate Blade Calibration Menu (Pitch Rod Calibration) 824
How to Operate Blade Calibration Menu (Machine Cal Step A) 827
How to Operate Blade Calibration Menu (Machine Cal Step B) 832
Calibrate IMU Sensor 846
How to Calibrate IMU Sensor 846
Reset Cylinder Stroke End 853
Reset Lift Cylinder Stroke End 853
Reset Tilt Cylinder Stroke End 854
Reset Angle Cylinder Stroke End 854
How to Input Wear Volume of Blade Edge and Track Shoes 856
Examine and Adjust Blade Elevation 857
Examine Blade Elevation (For Old Control Box) 857
Examine Blade Elevation (For New Control Box) 859
Adjust Blade Elevation (For Old Control Box) 862
Adjust Blade Elevation (For New Control Box) 863
Examine Stroke Sensor for Lift Cylinder 865
How to Examine Stroke Sensor for Lift Cylinder 865
Examine Stroke Sensor for Tilt Cylinder 867
How to Examine Stroke Sensor for Tilt Cylinder 867
Examine Stroke Sensor for Angle Cylinder 869
How to Examine Stroke Sensor for Angle Cylinder 869
Examine and Adjust Reset Sensor for Lift Cylinder 871
How to Examine Reset Sensor for Lift Cylinder 871
Adjust Reset Sensor for Lift Cylinder 872
Adjust When ICT Sensor Controller is Replaced 873
How to Adjust When ICT Sensor Controller is Replaced 873
How to Adjust When ICT Related Devices are Repaired or Replaced 876
Pm Clinic 879
Pm Clinic Service 879
Pm Clinic Check Sheet: D61EXI-24 881
Pm Clinic Check Sheet: D61PXI-24 888
Pm Clinic Check Sheet for Undercarriage: D61EXI-24 895
Pm Clinic Check Sheet for Undercarriage: D61PXI-24 898
40 Troubleshooting 901
Table of Contents 902
Precautions Before Work 914
Abbreviation List 915
Related Information to Troubleshooting 921
General Troubleshooting Points 921
Troubleshooting Points for Urea SCR System 922
Sequence of Events in Troubleshooting 936
Checks Before Troubleshooting 938
Inspection Procedure Before Troubleshooting 940
Walk-Around Check 940
Test in Accordance with Testing Procedure 942
Examine Fuel Level and Type 942
Examine for Impure Ingredient in Fuel 942
Examine DEF Level and Type 943
Examine Fuel Prefilter 943
Examine Fuel Main Filter 945
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 946
Examine Coolant Level (Reservoir Tank) 947
Examine Air Cleaner Clogging 948
Clean Outer Element 948
Replace Element 951
Examine Hydraulic Oil Level 951
Examine Hydraulic Oil Strainer 952
Examine Hydraulic Oil Filter 956
Examine Oil Level in Final Drive Case 957
Bleed Air from Fuel System 957
Bleed Air from Hydraulic System 957
How to Examine Electric Equipment 957
Preparation for Troubleshooting of Electrical System 964
Procedure for Troubleshooting 971
Symptom and Troubleshooting Numbers 974
Information Shown in Troubleshooting Table 979
Connector List and Layout (Machine with KOMTRAX Terminal) 981
Connector List and Layout (Machine with Gateway Function Controller) 997
Connector Contact Connection Table 1013
T-Branch Box and T-Branch Adapter Table 1053
Fuse Location Table (Machine with KOMTRAX Terminal) 1059
Fuse Location Table (Machine with Gateway Function Controller) 1063
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1067
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1071
Failure Code Table 1073
Troubleshooting by Failure Code (Display of Code) 1094
Failure Code [6091NX] 1094
Failure Code [989L00] 1096
Failure Code [989M00] 1097
Failure Code [989N00] 1098
Failure Code [A1U0N3] 1099
Failure Code [A1U0N4] 1101
Failure Code [A900FR] 1103
Failure Code [A900N6] 1104
Failure Code [A900NY] 1105
Failure Code [AA10NX] 1106
Failure Code [AB00KE] 1108
Failure Code [AQ10N3] 1110
Failure Code [AS00N3] 1112
Failure Code [AS00R2] 1114
Failure Code [AS00R3] 1115
Failure Code [AS00R4] 1116
Failure Code [AS00R5] 1117
Failure Code [AS00R6] 1118
Failure Code [AS00ZK] 1119
Failure Code [AS10KM] 1120
Failure Code [AS10NR] 1121
Failure Code [AS10NT] 1122
Failure Code [B@BAZG] 1123
Failure Code [B@BCNS] 1124
Failure Code [B@CRNS] 1125
Failure Code [B@CRZG] 1126
Failure Code [CA115] 1127
Failure Code [CA122] 1128
Failure Code [CA123] 1130
Failure Code [CA131] 1132
Failure Code [CA132] 1134
Failure Code [CA144] 1136
Failure Code [CA145] 1138
Failure Code [CA153] 1140
Failure Code [CA154] 1143
Failure Code [CA187] 1145
Failure Code [CA221] 1147
Failure Code [CA222] 1149
Failure Code [CA227] 1151
Failure Code [CA234] 1152
Failure Code [CA238] 1153
Failure Code [CA239] 1155
Failure Code [CA249] 1157
Failure Code [CA256] 1159
Failure Code [CA271] 1161
Failure Code [CA272] 1163
Failure Code [CA322] 1165
Failure Code [CA323] 1167
Failure Code [CA324] 1169
Failure Code [CA325] 1171
Failure Code [CA331] 1173
Failure Code [CA332] 1175
Failure Code [CA343] 1177
Failure Code [CA351] 1178
Failure Code [CA352] 1179
Failure Code [CA356] 1182
Failure Code [CA357] 1184
Failure Code [CA386] 1187
Failure Code [CA428] 1188
Failure Code [CA429] 1190
Failure Code [CA435] 1192
Failure Code [CA441] 1194
Failure Code [CA442] 1196
Failure Code [CA449] 1197
Failure Code [CA451] 1198
Failure Code [CA452] 1200
Failure Code [CA488] 1202
Failure Code [CA515] 1203
Failure Code [CA516] 1205
Failure Code [CA553] 1207
Failure Code [CA555] 1208
Failure Code [CA556] 1209
Failure Code [CA559] 1210
Failure Code [CA595] 1213
Failure Code [CA687] 1214
Failure Code [CA689] 1216
Failure Code [CA691] 1219
Failure Code [CA692] 1221
Failure Code [CA697] 1223
Failure Code [CA698] 1224
Failure Code [CA731] 1225
Failure Code [CA778] 1227
Failure Code [CA1117] 1232
Failure Code [CA1664] 1233
Failure Code [CA1669] 1236
Failure Code [CA1673] 1237
Failure Code [CA1677] 1238
Failure Code [CA1678] 1239
Failure Code [CA1682] 1240
Failure Code [CA1683] 1244
Failure Code [CA1684] 1246
Failure Code [CA1686] 1248
Failure Code [CA1691] 1249
Failure Code [CA1694] 1252
Failure Code [CA1695] 1255
Failure Code [CA1696] 1256
Failure Code [CA1712] 1258
Failure Code [CA1713] 1261
Failure Code [CA1714] 1263
Failure Code [CA1715] 1264
Failure Code [CA1776] 1265
Failure Code [CA1777] 1268
Failure Code [CA1843] 1271
Failure Code [CA1844] 1273
Failure Code [CA1879] 1276
Failure Code [CA1881] 1279
Failure Code [CA1883] 1281
Failure Code [CA1885] 1285
Failure Code [CA1887] 1287
Failure Code [CA1921] 1289
Failure Code [CA1922] 1292
Failure Code [CA1942] 1297
Failure Code [CA1993] 1298
Failure Code [CA2185] 1301
Failure Code [CA2186] 1303
Failure Code [CA2249] 1305
Failure Code [CA2271] 1306
Failure Code [CA2272] 1309
Failure Code [CA2288] 1312
Failure Code [CA2311] 1313
Failure Code [CA2349] 1314
Failure Code [CA2353] 1317
Failure Code [CA2357] 1319
Failure Code [CA2381] 1320
Failure Code [CA2382] 1323
Failure Code [CA2383] 1326
Failure Code [CA2386] 1329
Failure Code [CA2387] 1331
Troubleshooting Flowchart 1335
Failure Code [CA2555] 1336
Failure Code [CA2556] 1339
Failure Code [CA2637] 1342
Failure Code [CA2639] 1344
Failure Code [CA2771] 1347
Failure Code [CA2777] 1353
Failure Code [CA2976] 1356
Failure Code [CA3133] 1358
Failure Code [CA3134] 1360
Failure Code [CA3135] 1362
Failure Code [CA3142] 1366
Failure Code [CA3143] 1367
Failure Code [CA3144] 1368
Failure Code [CA3146] 1370
Failure Code [CA3147] 1371
Failure Code [CA3148] 1372
Failure Code [CA3151] 1374
Failure Code [CA3165] 1380
Failure Code [CA3229] 1382
Failure Code [CA3231] 1384
Failure Code [CA3232] 1386
Failure Code [CA3235] 1390
Failure Code [CA3239] 1392
Failure Code [CA3241] 1395
Failure Code [CA3242] 1398
Failure Code [CA3251] 1401
Failure Code [CA3253] 1403
Failure Code [CA3254] 1406
Failure Code [CA3255] 1409
Failure Code [CA3256] 1412
Failure Code [CA3311] 1414
Failure Code [CA3312] 1416
Failure Code [CA3313] 1419
Failure Code [CA3314] 1420
Failure Code [CA3315] 1421
Failure Code [CA3316] 1424
Failure Code [CA3317] 1425
Failure Code [CA3318] 1426
Failure Code [CA3319] 1429
Failure Code [CA3321] 1430
Failure Code [CA3322] 1432
Failure Code [CA3419] 1435
Failure Code [CA3421] 1437
Failure Code [CA3497] 1439
Failure Code [CA3498] 1440
Failure Code [CA3543] 1441
Failure Code [CA3545] 1448
Failure Code [CA3547] 1450
Failure Code [CA3558] 1451
Failure Code [CA3559] 1453
Failure Code [CA3562] 1455
Failure Code [CA3563] 1457
Failure Code [CA3567] 1460
Failure Code [CA3568] 1463
Failure Code [CA3571] 1469
Failure Code [CA3572] 1471
Failure Code [CA3574] 1473
Failure Code [CA3575] 1476
Failure Code [CA3577] 1478
Failure Code [CA3578] 1480
Failure Code [CA3582] 1482
Failure Code [CA3583] 1489
Failure Code [CA3596] 1491
Failure Code [CA3649] 1494
Failure Code [CA3681] 1496
Failure Code [CA3682] 1501
Failure Code [CA3713] 1507
Failure Code [CA3717] 1510
Failure Code [CA3718] 1511
Failure Code [CA3725] 1512
Failure Code [CA3741] 1515
Failure Code [CA3748] 1516
Failure Code [CA3751] 1518
Failure Code [CA3755] 1520
Failure Code [CA3866] 1522
Failure Code [CA3867] 1526
Failure Code [CA3868] 1529
Failure Code [CA3899] 1533
Failure Code [CA3911] 1535
Failure Code [CA3912] 1539
Failure Code [CA3932] 1541
Failure Code [CA3933] 1543
Failure Code [CA3934] 1545
Failure Code [CA3935] 1548
Failure Code [CA3936] 1550
Failure Code [CA4151] 1552
Failure Code [CA4152] 1556
Failure Code [CA4155] 1560
Failure Code [CA4156] 1563
Failure Code [CA4157] 1566
Failure Code [CA4158] 1568
Failure Code [CA4159] 1569
Failure Code [CA4161] 1570
Failure Code [CA4162] 1573
Failure Code [CA4163] 1576
Failure Code [CA4164] 1578
Failure Code [CA4165] 1580
Failure Code [CA4166] 1582
Failure Code [CA4168] 1584
Failure Code [CA4169] 1587
Failure Code [CA4171] 1589
Failure Code [CA4249] 1592
Failure Code [CA4251] 1594
Failure Code [CA4259] 1596
Failure Code [CA4261] 1599
Failure Code [CA4277] 1602
Failure Code [CA4281] 1606
Failure Code [CA4459] 1609
Failure Code [CA4461] 1612
Failure Code [CA4658] 1615
Failure Code [CA4731] 1619
Failure Code [CA4732] 1620
Failure Code [CA4739] 1621
Failure Code [CA4768] 1622
Failure Code [CA4769] 1624
Failure Code [CA4842] 1627
Failure Code [CA4952] (Machine with KOMTRAX Terminal) 1631
Failure Code [CA4952] (Machine with Gateway Function Controller) 1633
Failure Code [CA5115] 1635
Failure Code [CA5383] 1638
Failure Code [D130KA] 1640
Failure Code [D130KB] 1643
Failure Code [D130KY] 1645
Failure Code [D19JKZ] 1647
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1650
Failure Code [D811MC] (Machine with Gateway Function Controller) 1651
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1652
Failure Code [D862KA] (Machine with Gateway Function Controller) 1653
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1654
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1656
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1658
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1660
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 1662
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1664
Failure Code [D8G1KT] 1666
Failure Code [D8G6KT] 1667
Failure Code [DAF0MB] 1668
Failure Code [DAF0MC] 1669
Failure Code [DAF8KB] 1670
Failure Code [DAF9KQ] 1672
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1673
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1674
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 1675
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1677
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 1679
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1681
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1683
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1684
Failure Code [DAJ000] 1685
Failure Code [DAJ0KQ] 1686
Failure Code [DAJ0KT] 1687
Failure Code [DAJ0MC] 1688
Failure Code [DAJ1KK] 1689
Failure Code [DAJ2KK] 1691
Failure Code [DAJ5KK] 1693
Failure Code [DAJ6KK] 1696
Failure Code [DAJLKA] (Machine with KOMTRAX Terminal) 1698
Failure Code [DAJLKA] (Machine with Gateway Function Controller) 1700
Failure Code [DAJLKB] (Machine with KOMTRAX Terminal) 1702
Failure Code [DAJLKB] (Machine with Gateway Function Controller) 1704
Failure Code [DAJPMA] 1706
Failure Code [DAJQKR] (Machine with KOMTRAX Terminal) 1707
Failure Code [DAJQKR] (Machine with Gateway Function Controller) 1708
Failure Code [DAJRKR] 1709
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 1710
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1715
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal) 1720
Failure Code [DB2RKR] (Machine with Gateway Function Controller) 1725
Failure Code [DBR0KT] 1730
Failure Code [DBR0MC] 1731
Failure Code [DBR1KK] 1732
Failure Code [DBR2KK] 1735
Failure Code [DBR5KK] 1738
Failure Code [DBRLKA] 1740
Failure Code [DBRLKB] 1742
Failure Code [DBRPMA] 1744
Failure Code [DBRQKR] 1745
Failure Code [DBRRKR] 1747
Failure Code [DBTSKR] 1748
Failure Code [DBUTKA] 1751
Failure Code [DD12KA] 1752
Failure Code [DD12KB] 1754
Failure Code [DD13KA] 1756
Failure Code [DD13KB] 1758
Failure Code [DD14KA] 1760
Failure Code [DD14KB] 1762
Failure Code [DDKAKA] 1764
Failure Code [DDKAKB] 1766
Failure Code [DDKFL4] 1768
Failure Code [DDKGL4] 1770
Failure Code [DDKHKA] 1772
Failure Code [DDKHKB] 1774
Failure Code [DDKQKA] 1776
Failure Code [DDKQKB] 1778
Failure Code [DDKRKA] 1780
Failure Code [DDKRKB] 1782
Failure Code [DDKSKA] 1784
Failure Code [DDKSKB] 1786
Failure Code [DDNLKA] 1788
Failure Code [DDNLKB] 1790
Failure Code [DDP6KA] 1792
Failure Code [DDP6KB] 1795
Failure Code [DDP6MA] 1797
Failure Code [DDU1FS] 1799
Failure Code [DDU1KA] 1801
Failure Code [DDU1KY] 1804
Failure Code [DFA4KX] 1806
Failure Code [DFA4KZ] 1807
Failure Code [DFA4L8] 1808
Failure Code [DFA5KA] 1809
Failure Code [DFA5KB] 1812
Failure Code [DFA6KA] 1815
Failure Code [DFA6KB] 1818
Failure Code [DFA7KX] 1821
Failure Code [DFA7KZ] 1822
Failure Code [DFA7L8] 1823
Failure Code [DFA8KA] 1824
Failure Code [DFA8KB] 1827
Failure Code [DFA9KA] 1830
Failure Code [DFA9KB] 1833
Failure Code [DGS1KA] 1836
Failure Code [DGS1KX] 1839
Failure Code [DH21KA] 1840
Failure Code [DH21KB] 1842
Failure Code [DHA4KA] 1844
Failure Code [DHAAMA] 1846
Failure Code [DHACMA] 1848
Failure Code [DHH7KA] 1850
Failure Code [DHH7KB] 1853
Failure Code [DHH8KA] 1855
Failure Code [DHH8KB] 1858
Failure Code [DHH9KA] 1860
Failure Code [DHH9KB] 1863
Failure Code [DHHAKA] 1865
Failure Code [DHHAKB] 1868
Failure Code [DK30KA] 1870
Failure Code [DK30KB] 1873
Failure Code [DK30KX] 1875
Failure Code [DK30KZ] 1876
Failure Code [DK30L8] 1877
Failure Code [DK31KA] 1878
Failure Code [DK31KB] 1881
Failure Code [DK40KA] 1883
Failure Code [DK40KB] 1886
Failure Code [DK55KX] 1888
Failure Code [DK55KZ] 1889
Failure Code [DK55L8] 1890
Failure Code [DK56KA] 1891
Failure Code [DK56KB] 1894
Failure Code [DK57KA] 1896
Failure Code [DK57KB] 1899
Failure Code [DK80KA] 1901
Failure Code [DKS0L8] 1904
Failure Code [DKS1KA] 1905
Failure Code [DKS1KB] 1907
Failure Code [DKS2KA] 1909
Failure Code [DKS2KB] 1911
Failure Code [DKS3KA] 1913
Failure Code [DKS3KB] 1915
Failure Code [DKS3MB] 1917
Failure Code [DKS4L8] 1919
Failure Code [DKS5KA] 1920
Failure Code [DKS5KB] 1922
Failure Code [DKS6KA] 1924
Failure Code [DKS6KB] 1926
Failure Code [DKS7MB] 1928
Failure Code [DKSCL8] 1929
Failure Code [DKSDKA] 1930
Failure Code [DKSDKB] 1932
Failure Code [DKSEKA] 1934
Failure Code [DKSEKB] 1936
Failure Code [DKSFMB] 1938
Failure Code [DLM0KX] 1939
Failure Code [DLM0MA] 1940
Failure Code [DLM1KA] 1941
Failure Code [DLM1KB] 1943
Failure Code [DLM1MA] 1945
Failure Code [DLM2KA] 1946
Failure Code [DLM2KB] 1948
Failure Code [DLM2MA] 1950
Failure Code [DLM3KA] 1951
Failure Code [DLM3KB] 1953
Failure Code [DLM3MB] 1955
Failure Code [DN21FS] 1956
Failure Code [DR21KX] 1958
Failure Code [DR31KX] 1959
Failure Code [DV20KB] 1960
Failure Code [DW4BKA] 1962
Failure Code [DW4BKB] 1964
Failure Code [DW4BKY] 1966
Failure Code [DW7BKA] 1968
Failure Code [DW7BKB] 1970
Failure Code [DW7EKA] 1972
Failure Code [DW7EKB] 1974
Failure Code [DW7EKY] 1976
Failure Code [DWN5KA] 1978
Failure Code [DWN5KB] 1980
Failure Code [DWN5KY] 1982
Failure Code [DXA4KA] 1984
Failure Code [DXA4KB] 1986
Failure Code [DXA4KY] 1988
Failure Code [DXA5KA] 1990
Failure Code [DXA5KB] 1992
Failure Code [DXA5KY] 1994
Failure Code [DXA6KA] 1996
Failure Code [DXA6KB] 1998
Failure Code [DXA6KY] 2000
Failure Code [DXA7KA] 2002
Failure Code [DXA7KB] 2004
Failure Code [DXA7KY] 2006
Failure Code [DXHRKA] 2008
Failure Code [DXHRKB] 2010
Failure Code [DXHRKY] 2012
Failure Code [DXHSKA] 2014
Failure Code [DXHSKB] 2016
Failure Code [DXHSKY] 2018
Failure Code [DXHTKA] 2020
Failure Code [DXHTKB] 2022
Failure Code [DXHTKY] 2024
Failure Code [DXHUKA] 2026
Failure Code [DXHUKB] 2028
Failure Code [DXHUKY] 2030
Failure Code [DXJ4KA] 2032
Failure Code [DXJ4KB] 2034
Failure Code [DXJCKA] 2036
Failure Code [DXJCKB] 2038
Failure Code [DXJCKY] 2040
Failure Code [DXJDKA] 2042
Failure Code [DXJDKB] 2044
Failure Code [DXJDKY] 2046
Failure Code [DXK1KA] 2048
Failure Code [DXK1KB] 2050
Failure Code [DXK1KY] 2052
Failure Code [DXK2KA] 2054
Failure Code [DXK2KB] 2056
Failure Code [DXK2KY] 2058
Failure Code [F313KA] 2060
Failure Code [F313KB] 2061
Failure Code [F318KB] 2062
Failure Code [F318KY] 2063
Troubleshooting of Electrical System (E-Mode) 2064
Engine Does Not Start (Engine Does Not Crank) 2064
Manual Preheating System Does Not Operate 2071
Automatic Preheating System Does Not Operate 2074
While Preheating is in Operation, Preheating Monitor Does Not Come On 2076
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2078
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 2082
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2083
Charge Level Monitor Comes On in Red While Engine is in Operation 2084
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 2085
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 2086
HST Charge Pressure Monitor Comes On in Red While Engine Runs 2087
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2088
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs 2089
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2090
Fuel Gauge Does Not Show Normally 2091
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2094
Operation Mode Does Not Change 2095
When You Operate Customize Switch Does Not Show Customize Screen 2096
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 2097
Service Meter is Not Shown While Starting Switch is in OFF Position 2098
Service Mode Cannot be Selected 2099
Work Equipment Does Not Operate 2100
Foot Heater Does Not Operate 2102
Horn Does Not Sound 2108
Horn Does Not Stop 2110
Backup Alarm Does Not Sound 2111
Backup Alarm Does Not Stop Operation 2112
Headlamp Does Not Come On 2113
Rear Lamp Does Not Come On 2117
No Wiper Operates 2120
Front Wiper Does Not Operate 2122
Rear Wiper Does Not Operate 2124
Left Door Wiper Does Not Operate 2126
Right Door Wiper Does Not Operate 2130
Front Washer Does Not Operate 2134
Rear Washer Does Not Operate 2136
Left Door Washer Does Not Operate 2138
Right Door Washer Does Not Operate 2140
KOMTRAX System Does Not Operate Correctly 2142
Control Box Shuts Down After It Shows Messages [GPS receiver not connected!] and [Slope sensor not connected!] 2143
Control Box Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !] 2147
Control Box Shows Message [Waiting for radio link ] 2152
Control Box Shows Message [IMU sensor not connected] Show Production 2153
Control Box Shows Message [Waiting for satellites ] 2154
Control Box Shows Message [GPS receiver not connected!] Show Production 2155
Control Box Shows Message [Cylinder Stroke Reading Abnormal] 2157
Control Box Shows Message [Komatsu CAN Comms Abnormal] 2158
Control Box Shows Message [Komatsu Machine Trouble] 2159
Control Box Shows Message [Waiting to initialize ] 2160
Control Box Shows Message [System initializing] 2161
Control Box Shows Message [Initializing ] 2162
Control Box Shows Message [Configuring GPS] 2163
Control Box Shows Message [No GPS Localization ] 2164
Control Box Shows Message [Low precisions ] 2165
Control Box Shows Message [Heading Initializing] 2166
Control Box Displays [Out of design area ] 2167
Control Box Can Not be Turned on 2168
Control Box Does Not Display Intelligent Machine Control Screen 2169
Control Box Does Not Display Bulldozer Image 2170
Control Box Does Not Display Design Surface 2171
Control Box Touch Panel Does Not Respond 2172
Control Box Touch Panel is Inaccurate 2173
Cylinder Stroke Reset Indication Does Not Go Out 2174
AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes off) 2175
Blade Automatic Lower Control Does Not Start While AUTO is Shown 2177
Blade Automatic Raise Control Does Not Start While AUTO is Shown 2178
Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops) 2179
When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine 2180
Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface) 2181
Finished Surface is Inaccurate (The Finished Surface is Not Smooth) 2182
Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction) 2183
Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips) 2185
Machine Speed Does Not Increase While Blade Automatic Control is Activated 2186
Blade Tilt Angle Does Not Align with Design Surface 2187
Blade Tilts While Blade Automatic Control is Activated 2189
When Starting Switch is Turned to ON Position, REVERSE Leveling Mode Switch LED Does Not Come On or Does Not Go Out 2191
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2193
Information Shown in Troubleshooting Table (H-Mode) 2193
Failure Mode and Cause Table 2194
R H and L H Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) 2200
R H or L H Track Cannot Travel FORWARD and Reverse (One of R H or L H Travel Systems Cannot Operate) 2202
R H or L H Track Cannot Travel Forward or Reverse (Only One of the Travel Systems Cannot Operate in One Direction) 2204
Travel Speed or Power is Low 2206
Speed Range Does Not Change 2208
Shock is Large When Machine Moves Off or Stops 2209
Travel Deviation is Large 2210
Machine Drift on a Slope is Large 2213
Engine Speed Drops Largely or Engine Stops 2215
Unusual Noise is Heard from Around HST Pump or Motor 2217
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 2219
All Work Equipment Do Not Operate 2221
All Work Equipment Speed or Power is Low 2223
Blade Lift Speed or Power is Low 2224
Blade Tilt Speed or Power is Low 2226
Blade Angle Speed or Power is Low 2227
Time Lag of Blade Lift is Large 2228
Hydraulic Drift of Blade Lift is Large 2229
Hydraulic Drift of Tilted Blade is Large 2230
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 2231
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2232
Unusual Noise is Heard from Around Fan 2234
Troubleshooting of Engine (S-Mode) 2235
Information Shown in Troubleshooting Table (S-Mode) 2235
Engine Does Not Crank When Starting Switch is Turned to Start Position 2236
Engine Cranks but No Exhaust Smoke Comes Out 2237
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2238
Engine Startability is Unsatisfactory 2240
Engine Does Not Pick Up Smoothly 2242
Engine Stops During Operation 2244
Engine Does Not Rotate Smoothly 2246
Engine Lacks Output (or Lacks Power) 2247
KDPF Becomes Clogged in a Short Time 2249
Engine Oil Consumption is Excessive 2251
Engine Oil Becomes Dirty Quickly 2252
Fuel Consumption is Excessive 2253
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2254
Engine Oil Pressure Drops 2255
Fuel Mixes Into Engine Oil 2257
Water Mixes Into Engine Oil (Milky) 2258
Coolant Temperature Increases Too High (Overheat) 2259
Unusual Noise is Heard 2260
Vibration is Excessive 2261
Air Cannot be Bled from Fuel Circuit 2262
Active Regeneration is Done Frequently 2263
Active Regeneration Continues Long 2265
White Smoke is Exhausted During Active Regeneration 2266
DEF Consumption is Excessive 2267
There is an Unusual Smell (Irritating Odor) 2269
Foreign Materials Enter DEF (DEF Increases) 2270
50 Disassembly and Assembly 2271
Table of Contents 2272
Precautions Before Work 2277
Abbreviation List 2278
Related Information on Disassembly and Assembly 2284
How to Read This Manual 2284
Coating Materials List 2285
Special Tool List 2290
Sketches of Special Tools 2311
Engine and Cooling System 2324
Remove and Install Supply Pump Assembly 2324
Remove Supply Pump Assembly 2324
Install Supply Pump Assembly 2330
Remove and Install Injector Assembly 2337
How to Remove Injector Assembly 2337
How to Install Injector Assembly 2344
Remove and Install Cylinder Head Assembly 2354
How to Remove Cylinder Head Assembly 2354
How to Install Cylinder Head Assembly 2366
Remove and Install EGR Valve Assembly 2384
Remove EGR Valve Assembly 2384
Install EGR Valve Assembly 2385
Remove and Install EGR Cooler Assembly 2387
How to Remove EGR Cooler Assembly 2387
How to Install EGR Cooler Assembly 2389
Remove and Install Starter Assembly 2392
Remove Starting Motor Assembly 2392
Install Starting Motor Assembly 2394
Remove and Install Alternator Belt 2396
Remove Alternator Belt 2396
Install Alternator Belt 2397
Remove and Install Automatic Tensioner 2399
Remove Automatic Tensioner 2399
Install Automatic Tensioner 2399
Remove and Install Radiator Assembly 2400
How to Remove Radiator Assembly 2400
How to Install Radiator Assembly 2403
Remove and Install Hydraulic Oil Cooler Assembly 2407
How to Remove Hydraulic Oil Cooler Assembly 2407
How to Install Hydraulic Oil Cooler Assembly 2409
Remove and Install Aftercooler Assembly 2412
Remove Aftercooler Assembly 2412
Install Aftercooler Assembly 2415
Remove and Install Cooling Fan Drive Assembly 2419
Remove Cooling Fan Drive Assembly 2419
Install Cooling Fan Drive Assembly 2422
Remove and Install Cooling Fan Motor Assembly 2426
Remove Cooling Fan Motor Assembly 2426
Install Cooling Fan Motor Assembly 2429
Remove and Install Engine and HST Pump Assembly 2433
Remove Engine and HST Pump Assembly 2433
Install Engine and HST Pump Assembly 2442
Remove and Install Engine Front Oil Seal 2453
How to Remove Engine Front Oil Seal 2453
How to Install Engine Front Oil Seal 2454
Remove and Install Engine Rear Oil Seal 2456
How to Remove Engine Rear Oil Seal 2456
How to Install Engine Rear Oil Seal 2458
Remove and Install Engine Hood Assembly 2461
How to Remove Engine Hood Assembly 2461
How to Install Engine Hood Assembly 2464
Remove and Install Fuel Tank Assembly 2468
Remove Fuel Tank Assembly 2468
Install Fuel Tank Assembly 2474
Remove and Install DEF Tank Assembly 2480
How to Remove DEF Tank Assembly 2480
How to Install DEF Tank Assembly 2486
Remove and Install DEF Tank Sensor Flange Assembly 2492
How to Remove DEF Tank Sensor Flange Assembly 2492
How to Install DEF Tank Sensor Flange Assembly 2493
Remove and Install DEF Tank Sensor 2496
Remove DEF Tank Sensor 2496
Install DEF Tank Sensor 2497
Remove and Install DEF Tank Strainer 2504
Remove DEF Tank Strainer 2504
Install DEF Tank Strainer 2505
Remove and Install KDPF Assembly 2506
How to Remove KDPF Assembly 2507
How to Install KDPF Assembly 2510
Disassemble and Assemble KDPF Assembly 2513
Disassemble KDPF Assembly 2513
Assemble KDPF Assembly 2516
Remove and Install SCR Assembly 2523
How to Remove SCR Assembly 2523
How to Install SCR Assembly 2525
Remove and Install KDPF and SCR Assembly 2529
How to Remove KDPF and SCR Assembly 2530
Install KDPF and SCR Assembly 2536
Remove and Install KCCV Assembly 2543
Remove KCCV Assembly 2543
Install KCCV Assembly 2545
Remove and Install VGT Assembly 2547
How to Remove VGT Assembly 2547
How to Install VGT Assembly 2549
Remove and Install DEF Mixing Tube 2552
Remove DEF Mixing Tube 2552
Install DEF Mixing Tube 2554
Remove and Install DEF Injector 2558
Remove DEF Injector 2558
Install DEF Injector 2561
Remove and Install DEF Pump 2565
Remove DEF Pump 2565
Install DEF Pump 2568
Remove and Install DEF Hose 2571
Remove DEF Hose 2571
Install DEF Hose 2575
Remove and Install Air Cleaner Assembly 2581
Remove Air Cleaner Assembly 2581
Install Air Cleaner Assembly 2583
Remove and Install Air Conditioner Compressor Assembly 2586
Remove Air Conditioner Compressor Assembly 2586
How to Install Air Conditioner Compressor Assembly 2587
Remove and Install Air Conditioner Condenser Assembly 2589
How to Remove Air Conditioner Condenser Assembly 2589
How to Install Air Conditioner Condenser Assembly 2593
Power Train 2597
Remove and Install Damper Assembly 2597
How to Remove Damper Assembly 2597
How to Install Damper Assembly 2598
Remove and Install HST Pump Assembly 2600
Remove HST Pump Assembly 2600
Install HST Pump Assembly 2602
Remove and Install HST Motor and Final Drive Assembly 2604
Remove HST Motor and Final Drive Assembly 2604
Install HST Motor and Final Drive Assembly 2607
Disassemble and Assemble Final Drive Assembly 2610
Disassemble Final Drive Assembly 2611
Assemble Final Drive Assembly 2616
Undercarriage and Frame 2625
Remove and Install Track Frame Assembly 2625
Remove Track Frame Assembly 2625
Install Track Frame Assembly 2629
Remove and Install Idler Assembly 2634
Remove Idler Assembly 2634
Install Idler Assembly 2636
Disassemble and Assemble Idler Assembly 2638
Disassemble Idler Assembly 2638
Assemble Idler Assembly 2640
Remove and Install Recoil Spring Assembly 2645
Remove Recoil Spring Assembly 2645
Install Recoil Spring Assembly 2646
Disassemble and Assemble Recoil Spring Assembly 2647
Disassemble Recoil Spring Assembly 2647
Assemble Recoil Spring Assembly 2650
Remove and Install Track Roller Assembly 2653
Remove Track Roller Assembly 2653
Install Track Roller Assembly 2654
Disassemble and Assemble Track Roller Assembly 2657
Disassemble Track Roller Assembly 2657
Assemble Track Roller Assembly 2659
Remove and Install Carrier Roller Assembly 2663
Remove Carrier Roller Assembly 2663
Install Carrier Roller Assembly 2664
Disassemble and Assemble Carrier Roller Assembly 2666
Disassemble Carrier Roller Assembly 2666
Assemble Carrier Roller Assembly 2667
Remove and Install Pivot Shaft Assembly 2670
Remove Pivot Shaft Assembly 2670
Install Pivot Shaft Assembly 2671
Separate and Connect Track Assembly 2673
Examine Before Separation of Track Assembly 2673
Separate Track Assembly (Standard) 2674
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2675
Install Track Assembly 2676
Separate and Connect PLUS Type Track Assembly 2678
Separate PLUS Type Track Assembly Generally 2678
Install PLUS Type Track Assembly 2678
Disassemble and Assemble Track Assembly Generally 2680
How to Disassemble Full Track Shoes Assembly 2680
How to Assemble Full Track Shoes Assembly 2685
Disassemble and Assemble PLUS Type Track Assembly Generally 2698
Disassemble PLUS Type Track Assembly Generally 2699
How to Assemble PLUS Type Track Shoes Assembly Generally 2700
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2715
Disassemble One Track Link Assembly in Field (Track Assembly) 2716
Assemble One Track Link Assembly in Field (Track Assembly) 2717
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2724
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2725
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2727
Remove and Install Equalizer Bar Assembly 2731
Remove Equalizer Bar Assembly 2731
Install Equalizer Bar Assembly 2733
Remove and Install Equalizer Bar Side Bushing 2736
How to Remove Equalizer Bar Side Bushings 2736
How to Install Equalizer Bar Side Bushings 2736
Remove and Install Segment Teeth 2738
Remove Segment Teeth 2738
Install Segment Teeth 2739
Hydraulic System 2740
Remove and Install Hydraulic Tank Assembly 2740
Remove Hydraulic Tank Assembly 2741
How to Install Hydraulic Tank Assembly 2745
Remove and Install Control Valve Assembly 2750
How to Remove Control Valve Assembly 2750
How to Install Control Valve Assembly 2755
Work Equipment 2760
Remove and Install Blade Assembly 2760
Remove Blade Assembly 2760
Install Blade Assembly 2762
Remove and Install Work Equipment Assembly 2766
Remove Work Equipment Assembly 2766
Install Work Equipment Assembly 2770
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2773
Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly 2773
Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2775
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2778
Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2779
Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2783
Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly 2791
Remove Stroke Sensing Blade Tilt Cylinder Assembly 2791
Install Stroke Sensing Blade Tilt Cylinder Assembly 2794
Disassemble and Assemble Stroke Sensing Blade Tilt Cylinder Assembly 2799
Disassemble Stroke Sensing Blade Tilt Cylinder Assembly 2800
Assemble Stroke Sensing Blade Tilt Cylinder Assembly 2803
Remove and Install Stroke Sensing Blade Angle Cylinder Assembly 2808
Remove Stroke Sensing Blade Angle Cylinder Assembly 2808
Install Stroke Sensing Blade Angle Cylinder Assembly 2811
Disassemble and Assemble Stroke Sensing Blade Angle Cylinder Assembly 2815
Disassemble Stroke Sensing Blade Angle Cylinder Assembly 2816
Assemble Stroke Sensing Blade Angle Cylinder Assembly 2819
Remove and Install U-Frame Assembly 2825
Remove U-Frame Assembly 2825
Install U-Frame Assembly 2828
CAB Related Parts 2831
Remove and Install Operator Cab Assembly 2831
How to Remove Operator Cab Assembly 2831
Install Operator CAB Assembly 2839
Remove and Install Operator Cab Glass (Adhered Glass) 2847
Remove Operator CAB Glass (Adhered Glass) 2849
Install Operator CAB Glass (Adhered Glass) 2849
Remove and Install Air Conditioner Unit Assembly 2855
Remove Air Conditioner Unit Assembly 2855
Install Air Conditioner Unit Assembly 2861
Remove and Install Operator Seat 2868
Remove Operator’s Seat 2868
Install Operator’s Seat 2869
How to Remove and Install Seat Belt 2870
How to Remove Seat Belt 2870
How to Install Seatbelt 2870
Remove and Install Foot Heater Assembly 2872
Remove Foot Heater Assembly 2872
Install Foot Heater Assembly 2874
Disassemble and Assemble Foot Heater Assembly 2877
Disassemble Foot Heater Assembly 2877
Assemble Foot Heater Assembly 2878
Electrical System 2879
Remove and Install Engine Controller Assembly 2879
Remove Engine Controller Assembly 2879
Install Engine Controller Assembly 2881
Remove and Install HST Controller Assembly 2884
Remove HST Controller Assembly 2884
How to Install HST Controller Assembly 2885
Remove and Install Machine Monitor Assembly 2886
Remove Machine Monitor Assembly 2886
Install Machine Monitor Assembly 2887
Remove and Install Mass Air Flow and Temperature Sensor 2889
How to Remove Mass Air Flow and Temperature Sensor 2889
How to Install Mass Air Flow and Temperature Sensor 2891
Remove and Install KCCV Crankcase Pressure Sensor 2892
How to Remove KCCV Crankcase Pressure Sensor 2892
How to Install KCCV Crankcase Pressure Sensor 2894
Remove and Install SCR Temperature Sensor 2896
Remove SCR Temperature Sensor 2896
Install SCR Temperature Sensor 2897
Remove and Install KOMTRAX Terminal Assembly 2899
Remove KOMTRAX Terminal Assembly 2899
Install KOMTRAX Terminal Assembly 2900
Remove and Install Gateway Function Controller Assembly 2901
How to Remove Gateway Function Controller Assembly 2901
How to Install Gateway Function Controller Assembly 2902
Remove and Install Communication Terminal 2903
How to Remove Communication Terminal 2903
How to Install Communication Terminal 2906
Remove and Install ICT Sensor Controller Assembly 2909
Remove ICT Sensor Controller Assembly 2909
Install ICT Sensor Controller Assembly 2909
Remove and Install Control Box 2911
How to Remove Control Box (For Old Control Box) 2911
How to Remove Control Box (For New Control Box) 2912
How to Install Control Box (For Old Control Box) 2912
How to Install Control Box (For New Control Box) 2913
Remove and Install GNSS Receiver 2915
Remove GNSS Receiver 2915
Install GNSS Receiver 2915
Remove and Install GNSS Antenna 2917
Remove GNSS Antenna 2917
Install GNSS Antenna 2918
Remove and Install IMU Sensor 2923
Remove IMU Sensor 2923
Install IMU Sensor 2925
60 Maintenance Standard 2929
Table of Contents 2930
Abbreviation List 2932
Engine and Cooling System 2938
Maintenance Standard for Engine Mount 2938
Maintenance Standard for Damper 2939
Maintenance Standard for Cooling System 2940
Maintenance Standard for Cooling Fan Motor 2942
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 2944
Power Train 2945
Maintenance Standard for HST Pump 2945
Maintenance Standard for EPC Valve of HST Pump 2946
Maintenance Standard for Tow Receiving Valve of HST Pump 2947
Maintenance Standard for HST Charge Pump 2948
Maintenance Standard for HST Motor 2950
Maintenance Standard for Final Drive 2951
Maintenance Standard for Sprocket for Conventional Type Track Shoes 2953
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2954
Maintenance Standard for Sprocket for PLUS Type Track Shoes 2956
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2957
Undercarriage and Frame 2959
Maintenance Standard for Suspension 2959
Maintenance Standard for Track Frame and Idler Cushion 2961
Maintenance Standard for Idler 2963
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2965
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2966
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2967
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2968
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2969
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 2970
Maintenance Standard for Conventional Type Track Shoes 2971
Maintenance Standard for PLUS Type Track Shoes 2973
Maintenance Standard for Single Shoes 2975
Maintenance Standard for Swamp Shoes 2976
Hydraulic System 2977
Maintenance Standard for Hydraulic Tank 2977
Maintenance Standard for Work Equipment and Cooling Fan Pump 2978
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump 2979
Maintenance Standard for Control Valve 2981
Maintenance Standard for Ripper PPC Valve 2988
Maintenance Standard for 5-Spool EPC and Solenoid Valve 2990
Maintenance Standard for EPC Valve 2991
Maintenance Standard for Angle Control EPC Valve 2992
Maintenance Standard for Quick Drop Valve 2993
Work Equipment 2995
Maintenance Standard for Front Work Equipment 2995
Maintenance Standard for Cutting Edge and End Bit 2998
Maintenance Standard for Blade Lift Cylinder 2999
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder 3000
Maintenance Standard for Blade Tilt Cylinder 3001
Maintenance Standard for Stroke Sensing Blade Tilt Cylinder 3002
Maintenance Standard for Blade Angle Cylinder 3003
Maintenance Standard for Stroke Sensing Blade Angle Cylinder 3004
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder 3005
Maintenance Standard for Stroke Sensor for Blade Tilt Cylinder 3006
Maintenance Standard for Stroke Sensor for Blade Angle Cylinder 3007
Maintenance Standard for Fixed Multi-Shank Ripper 3008
Maintenance Standard for Ripper Lift Cylinder 3010
CAB Related Parts 3011
Maintenance Standard for CAB Mount 3011
Electrical System 3012
Maintenance Standard for Steering Electric Lever 3012
80 Appendix 3013
Table of Contents 3014
Precautions Before Work 3015
Abbreviation List 3016
Air Conditioner System 3022
Precautions for Refrigerant 3022
Air Conditioner Component 3023
Specifications of Air Conditioner 3026
Structure and Function of Refrigeration Cycle 3027
Outline of Refrigeration Cycle 3028
Component Parts of Air Conditioner System 3030
Air Conditioner Unit 3030
Configuration Diagram of Air Conditioner Unit 3030
Function of Air Conditioner Unit 3031
Component Parts of Air Conditioner Unit 3032
Function of Evaporator as Air Conditioner Unit Component 3032
Function of Heater Core as Air Conditioner Unit Component 3032
Function of Thermostat as Air Conditioner Unit Component 3032
Structure of Expansion Valve as Air Conditioner Unit Component 3033
Function of Expansion Valve as Air Conditioner Unit Component 3033
Operate Expansion Valve as Air Conditioner Unit Component 3033
Function of Dual Pressure Switch 3034
Function of Pressure Switch 3034
Compressor 3035
Structure of Compressor 3035
Specifications of Compressor 3035
Function of Compressor 3035
Condenser 3036
Structure of Condenser 3036
Specifications of Condenser 3036
Function of Condenser 3037
Receiver Drier 3038
Structure of Receiver Dryer 3038
Specifications of Receiver Dryer 3038
Function of Receiver Dryer 3038
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3040
Circuit Diagram of Air Conditioner 3043
System Diagram of Air Conditioner 3044
Control Function of Air Conditioner 3045
Locations of Air Conditioner Parts and Layout of Connectors 3046
Examine Relay 3050
How to Examine Relay 3050
Air Conditioner Troubleshooting Chart 1 3052
Air Conditioner Troubleshooting Chart 2 3053
Information Shown in Troubleshooting Table 3056
Troubleshooting for Condenser Fan 3057
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3060
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3064
Troubleshooting for Temperature Control Function 3067
Troubleshooting by Gauge Pressure 3071
Connect Service Tool 3073
How to Connect Service Tool 3073
Precautions for Disconnection and Connection of Air Conditioner Piping 3074
Handle Compressor Oil 3076
90 Circuit Diagrams 3079
Table of Contents 3080
Abbreviation List 3081
Hydraulic Circuit Diagram 3087
Symbols Used in Hydraulic Circuit Diagram 3087
Hydraulic Circuit Diagram 3091
Electrical Circuit Diagram 3093
Symbols Used in Electric Circuit Diagram 3093
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/14) 3097
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/14) 3099
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/14) 3101
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/14) 3103
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/14) 3105
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/14) 3107
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/14) 3109
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/14) 3111
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/14) 3113
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/14) 3115
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/14) 3117
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (12/14) 3119
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (13/14) 3121
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (14/14) 3123
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/16) 3125
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/16) 3127
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/16) 3129
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/16) 3131
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/16) 3133
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/16) 3135
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/16) 3137
Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/16) 3139
Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/16) 3141
Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/16) 3143
Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/16) 3145
Electrical Circuit Diagram (Machine with Gateway Function Controller) (12/16) 3147
Electrical Circuit Diagram (Machine with Gateway Function Controller) (13/16) 3149
Electrical Circuit Diagram (Machine with Gateway Function Controller) (14/16) 3151
Electrical Circuit Diagram (Machine with Gateway Function Controller) (15/16) 3153
Electrical Circuit Diagram (Machine with Gateway Function Controller) (16/16) 3155
INDEX 3157

S.V  21/12/24