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

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Komatsu D61EXi-24,D61EXi-24E0,D61PXi-24,D61PXi-24E0 Bulldozer Shop Manual KEBM685605 – PDF DOWNLOAD

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Komatsu D61EXi-24,D61EXi-24E0,D61PXi-24,D61PXi-24E0 Bulldozer Shop Manual KEBM685605 – PDF DOWNLOAD

Language : English
Pages : 3232
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D61EXi-24,D61EXi-24E0,D61PXi-24,D61PXi-24E0 Bulldozer Shop Manual KEBM685605 – PDF DOWNLOAD

SERIAL NUMBERS

• D61EXi-B65001 and up
• D61PXi-B65001 and up

COVER 0
00 INDEX AND FOREWORD . 3
INDEX . 4
FOREWORD, SAFETY, BASIC INFORMATION . 24
HOW TO READ THE SHOP MANUAL . 24
SAFETY NOTICE FOR OPERATION . 26
PRECAUTIONS TO PREVENT FIRE . 34
ACTIONS IF FIRE OCCURS 36
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 37
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 38
PRECAUTIONS FOR DEF . 39
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 39
PRECAUTIONS FOR ADDING 39
PRECAUTIONS FOR STORING . 39
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 39
THE OTHER PRECAUTIONS . 39
STORE AdBlue/DEF 40
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 41
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 44
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 51
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 53
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 54
PRACTICAL USE OF KOMTRAX 55
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 58
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 60
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 64
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 70
HOW TO READ ELECTRICAL WIRE CODE 71
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 75
STANDARD TIGHTENING TORQUE TABLE 78
CONVERSION TABLE 85
ABBREVIATION LIST . 90
01 SPECIFICATION 93
CONTENTS 94
SPECIFICATIONS 95
SPECIFICATION DRAWING . 95
SPECIFICATION DRAWING: D61EXI-24 95
SPECIFICATION DRAWING: D61EXI-24E0 97
SPECIFICATION DRAWING: D61PXI-24 99
SPECIFICATION DRAWING: D61PXI-24E0 101
SPECIFICATIONS 103
SPECIFICATIONS: D61EXI-24 . 103
SPECIFICATIONS: D61EXI-24E0 . 109
SPECIFICATIONS: D61PXI-24 . 114
SPECIFICATIONS: D61PXI-24E0 . 119
WEIGHT TABLE 124
WEIGHT TABLE: D61EXI-24 . 124
WEIGHT TABLE: D61EXI-24E0 . 126
WEIGHT TABLE: D61PXI-24 . 128
WEIGHT TABLE: D61PXI-24E0 . 130
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) . 132
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 132
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 134
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 134
10 STRUCTURE AND FUNCTION . 137
CONTENTS 138
UREA SCR SYSTEM . 142
LAYOUT DRAWING OF UREA SCR SYSTEM . 142
UREA SCR SYSTEM DIAGRAM . 145
FUNCTION OF UREA SCR SYSTEM . 146
FUNCTION OF AdBlue/DEF SYSTEM . 146
INDUCEMENT STRATEGY . 148
COMPONENT PARTS OF UREA SCR SYSTEM 162
AdBlue/DEF MIXING TUBE 162
SCR ASSEMBLY 163
AdBlue/DEF TANK . 165
AdBlue/DEF PUMP . 167
AdBlue/DEF INJECTOR . 168
AdBlue/DEF HOSE . 169
AdBlue/DEF TANK HEATING VALVE . 170
BOOT-UP SYSTEM 171
LAYOUT DRAWING OF BOOT-UP SYSTEM 171
SYSTEM OPERATING LAMP SYSTEM 172
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM 172
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 172
BATTERY DISCONNECT SWITCH . 174
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH . 174
FUNCTION OF BATTERY DISCONNECT SWITCH . 174
ENGINE SYSTEM . 176
LAYOUT DRAWING OF ENGINE SYSTEM . 176
ENGINE CONTROL SYSTEM . 178
LAYOUT OF ENGINE CONTROL SYSTEM . 178
ENGINE CONTROL SYSTEM DIAGRAM . 180
FUNCTION OF ENGINE CONTROL SYSTEM . 182
AUTOMATIC IDLE STOP SYSTEM 184
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 184
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 184
COMPONENT PARTS OF ENGINE SYSTEM 187
DAMPER 187
VGT . 188
EGR SYSTEM 192
EGR VALVE . 194
EGR COOLER 196
KCCV SYSTEM . 198
KCCV VENTILATOR . 200
KDPF 202
COOLING SYSTEM 206
LAYOUT DRAWING OF COOLING SYSTEM 206
SPECIFICATIONS OF COOLING SYSTEM 207
COOLING FAN CONTROL SYSTEM 208
COOLING FAN CONTROL SYSTEM DIAGRAM 208
FUNCTION OF COOLING FAN CONTROL SYSTEM 209
COMPONENT PARTS OF COOLING SYSTEM . 211
COOLING FAN MOTOR . 211
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE . 216
HYDRAULIC OIL COOLER BYPASS VALVE . 218
HST CHARGE SAFETY VALVE . 219
CONTROL SYSTEM 221
LAYOUT DRAWING OF CONTROL SYSTEM 221
MACHINE MONITOR SYSTEM 222
SYSTEM DIAGRAM OF MACHINE MONITOR . 222
FUNCTION OF MACHINE MONITOR SYSTEM 222
KOMTRAX SYSTEM 223
KOMTRAX SYSTEM DIAGRAM 223
FUNCTION OF KOMTRAX SYSTEM 223
COMPONENT PARTS OF CONTROL SYSTEM . 224
MACHINE MONITOR . 224
GATEWAY FUNCTION CONTROLLER . 240
COMMUNICATION TERMINAL 243
HST CONTROLLER 245
ENGINE CONTROLLER . 249
DECELERATOR AND BRAKE POTENTIOMETER . 256
HYDRAULIC SYSTEM 258
LAYOUT DRAWING OF HYDRAULIC SYSTEM 258
CLSS 259
STRUCTURE OF CLSS . 259
FUNCTION OF CLSS 260
COMPONENT PARTS OF HYDRAULIC SYSTEM . 262
HYDRAULIC TANK 262
WORK EQUIPMENT AND COOLING FAN PUMP . 264
LS VALVE 272
PC VALVE 273
CONTROL VALVE . 276
POWER TRAIN SYSTEM 297
LAYOUT DRAWING OF HST SYSTEM 297
OPERATION OF HST SYSTEM . 298
STEERING AND BRAKE CONTROL SYSTEM . 300
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM . 300
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM . 300
HST CONTROL SYSTEM 302
HST CONTROL SYSTEM DIAGRAM 302
GEAR SHIFT CONTROL FUNCTION . 303
ENGINE LOW SPEED MATCHING CONTROL FUNCTION 307
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION 307
DECELERATION AND BRAKE CONTROL FUNCTION . 309
GEAR SHIFT CONTROL FUNCTION BY LOAD . 310
TURN CONTROL FUNCTION . 310
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION . 311
PARKING BRAKE CONTROL SYSTEM 313
PARKING BRAKE CONTROL SYSTEM DIAGRAM 313
FUNCTION OF PARKING BRAKE CONTROL SYSTEM 314
OPERATION OF PARKING BRAKE CONTROL SYSTEM . 315
COMPONENT PARTS OF POWER TRAIN SYSTEM . 316
HST PUMP 316
HST CHARGE PUMP . 333
HST MOTOR . 334
FINAL DRIVE . 346
ELECTRIC STEERING CONTROL LEVER . 350
WORK EQUIPMENT SYSTEM . 353
WORK EQUIPMENT CONTROL 353
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM . 353
FUNCTION OF WORK EQUIPMENT CONTROL 354
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 356
LAYOUT OF FIXED MULTI-SHANK RIPPER 357
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 358
RIPPER PPC VALVE 358
5-PORT VALVE OF EPC AND SOLENOID 362
PILOT CIRCUIT ACCUMULATOR . 368
ANGLE CONTROL EPC VALVE . 369
QUICK DROP VALVE 372
PISTON VALVE 374
ELECTRIC BLADE CONTROL LEVER 375
ICT SYSTEM 377
LAYOUT DRAWING OF ICT SYSTEM 377
SYSTEM DIAGRAM OF ICT CONTROL SYSTEM 379
BLADE CONTROL SYSTEM 381
FUNCTION OF BLADE CONTROL SYSTEM 381
SIMPLE GRADING MODE SYSTEM DIAGRAM 383
FUNCTION OF SIMPLE GRADING MODE . 384
OPERATION OF SIMPLE GRADING MODE 384
ASSIST CONTROL SYSTEM . 386
ASSIST CONTROL SYSTEM DIAGRAM . 386
FUNCTION OF ASSIST CONTROL SYSTEM . 386
OPERATION OF ASSIST CONTROL SYSTEM 387
BACK GRADE MODE SYSTEM 388
BACK GRADE MODE SYSTEM DIAGRAM 388
FUNCTION OF BACK GRADE MODE SYSTEM 389
OPERATION OF BACK GRADE MODE SYSTEM . 389
CUT CONTROL SYSTEM 390
CUT CONTROL SYSTEM DIAGRAM 390
FUNCTION OF CUT CONTROL SYSTEM 391
OPERATION OF CUT CONTROL SYSTEM . 391
SMOOTH START SYSTEM . 403
SMOOTH START SYSTEM DIAGRAM . 403
FUNCTION OF SMOOTH START SYSTEM . 404
OPERATION OF SMOOTH START SYSTEM 404
SLIP CONTROL SYSTEM . 405
SLIP CONTROL SYSTEM DIAGRAM . 405
FUNCTION OF SLIP CONTROL SYSTEM . 406
OPERATION OF SLIP CONTROL SYSTEM 406
SPEED CONTROL SYSTEM 407
SPEED CONTROL SYSTEM DIAGRAM 407
FUNCTION OF SPEED CONTROL SYSTEM 407
OPERATION OF SPEED CONTROL SYSTEM . 407
STRAIGHT TRAVEL CORRECTION SYSTEM . 409
STRAIGHT TRAVEL CORRECTION SYSTEM DIAGRAM . 409
FUNCTION OF STRAIGHT TRAVEL CORRECTION SYSTEM . 410
OPERATION OF STRAIGHT TRAVEL CORRECTION SYSTEM 410
QUICK SURFACE CONTROL SYSTEM 413
QUICK SURFACE CONTROL SYSTEM DIAGRAM 413
FUNCTION OF QUICK SURFACE CONTROL SYSTEM 413
OPERATION OF QUICK SURFACE CONTROL SYSTEM . 414
SYSTEM OF TRIANGULATED SURFACE FROM AS-BUILT 415
SYSTEM DIAGRAM OF TRIANGULATED SURFACE FROM AS-BUILT 415
FUNCTION OF SYSTEM OF TRIANGULATED SURFACE FROM AS-BUILT 415
OPERATION OF SYSTEM OF TRIANGULATED SURFACE FROM AS-BUILT . 415
2 SURFACES SELECTION CONTROL SYSTEM . 417
2 SURFACES SELECTION CONTROL SYSTEM DIAGRAM . 417
FUNCTION OF 2 SURFACES SELECTION CONTROL SYSTEM . 418
OPERATION OF 2 SURFACES SELECTION CONTROL SYSTEM 418
LIFT LAYER CONTROL SYSTEM . 419
LIFT LAYER CONTROL SYSTEM DIAGRAM . 419
FUNCTION OF LIFT LAYER CONTROL SYSTEM . 420
OPERATION OF LIFT LAYER CONTROL SYSTEM 420
2D LASER MACHINE CONTROL SYSTEM . 422
SYSTEM DIAGRAM OF 2D LASER MACHINE CONTROL SYSTEM . 422
FUNCTION OF 2D LASER MACHINE CONTROL SYSTEM . 423
OPERATION OF 2D LASER MACHINE CONTROL SYSTEM 423
COMPONENT PARTS OF ICT SYSTEM . 424
ICT SENSOR CONTROLLER . 424
CONTROL BOX . 428
GNSS RECEIVER . 430
GNSS ANTENNA 432
IMU SENSOR 433
GNSS EXTERNAL RADIO DEVICE 436
NAVIGATION CONTROLLER . 438
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER . 443
STROKE SENSOR FOR BLADE TILT CYLINDER . 446
STROKE SENSOR FOR BLADE ANGLE CYLINDER 448
UNDERCARRIAGE AND FRAME . 450
MAIN FRAME 450
STRUCTURE OF MAIN FRAME . 450
SUSPENSION 451
STRUCTURE OF SUSPENSION . 451
SPECIFICATIONS OF SUSPENSION 452
FUNCTION OF SUSPENSION 453
TRACK FRAME AND IDLER CUSHION . 454
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 454
FUNCTION OF TRACK FRAME AND IDLER CUSHION . 455
WORK EQUIPMENT 457
STRUCTURE OF FRONT WORK EQUIPMENT . 457
STRUCTURE OF FIXED MULTI-SHANK RIPPER . 458
CAB AND ITS ATTACHMENTS . 459
ROPS CAB 459
STRUCTURE OF ROPS CAB . 459
FUNCTION OF ROPS CAB 460
CAB MOUNT . 461
STRUCTURE OF CAB MOUNT 461
FUNCTION OF CAB MOUNT . 461
20 STANDARD VALUE TABLE . 463
CONTENTS 464
STANDARD VALUE TABLE FOR ENGINE . 465
STANDARD VALUE TABLE FOR ENGINE: D61EXI-24 465
STANDARD VALUE TABLE FOR ENGINE: D61EXI-24E0 469
STANDARD VALUE TABLE FOR ENGINE: D61PXI-24 473
STANDARD VALUE TABLE FOR ENGINE: D61PXI-24E0 477
STANDARD VALUE TABLE FOR MACHINE 481
STANDARD VALUE TABLE FOR MACHINE: D61EXI-24 . 481
STANDARD VALUE TABLE FOR MACHINE: D61EXI-24E0 . 498
STANDARD VALUE TABLE FOR MACHINE: D61PXI-24 . 515
STANDARD VALUE TABLE FOR MACHINE: D61PXI-24E0 . 532
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 549
30 TESTING AND ADJUSTING 551
CONTENTS 552
RELATED INFORMATION ON TESTING AND ADJUSTING 556
TOOLS FOR TESTING AND ADJUSTING . 556
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 564
ENGINE AND COOLING SYSTEM . 569
TEST ENGINE SPEED . 569
METHOD FOR TESTING ENGINE SPEED . 569
TEST BOOST PRESSURE . 571
METHOD FOR TESTING BOOST PRESSURE . 571
TEST EXHAUST GAS COLOR 573
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 573
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 575
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 577
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 577
TEST AND ADJUST VALVE CLEARANCE . 579
METHOD FOR TESTING VALVE CLEARANCE 579
METHOD FOR ADJUSTING VALVE CLEARANCE 580
TEST COMPRESSION PRESSURE . 581
METHOD FOR TESTING COMPRESSION PRESSURE . 581
TEST BLOWBY PRESSURE 586
METHOD FOR TESTING BLOWBY PRESSURE 586
TEST ENGINE OIL PRESSURE 589
METHOD FOR TESTING ENGINE OIL PRESSURE 589
TEST EGR VALVE AND VGT OIL PRESSURE . 590
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 590
TEST FUEL PRESSURE 592
METHOD FOR TESTING FUEL PRESSURE 593
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 598
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 599
BLEEDING AIR FROM FUEL SYSTEM . 605
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 605
TEST FUEL CIRCUIT FOR LEAKAGE . 606
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 606
HANDLE CYLINDER CUT-OUT MODE OPERATION 608
HANDLE NO-INJECTION CRANKING OPERATION 609
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 610
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 610
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 611
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 611
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS . 612
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS . 612
TEST ALTERNATOR BELT 613
METHOD FOR REMOVING ALTERNATOR BELT . 613
TEST AUTOMATIC TENSIONER 615
METHOD FOR TESTING AUTOMATIC TENSIONER 615
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 617
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 617
TEST SCR RELATED FUNCTIONS 618
TEST AdBlue/DEF PUMP RAISED PRESSURE 622
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 625
TEST AdBlue/DEF LINE HEATER RELAY 1 . 630
TEST AdBlue/DEF LINE HEATER RELAY 2 . 633
TEST AdBlue/DEF PUMP HEATER RELAY . 636
TEST AdBlue/DEF TANK HEATER VALVE . 640
TEST DENITRATION EFFICIENCY OF SCR 644
CLEAN AdBlue/DEF TANK . 647
METHOD FOR CLEANING AdBlue/DEF TANK . 647
CLEAN AdBlue/DEF TANK MOUNTING PORTION 651
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 651
CLEAN AdBlue/DEF PUMP . 652
CLEAN AdBlue/DEF PUMP . 652
POWER TRAIN . 658
TEST AND ADJUST HST OIL PRESSURE 658
METHOD FOR TESTING HST OIL PRESSURE . 658
METHOD FOR ADJUSTING HST OIL PRESSURE . 661
BLEED AIR FROM HST PUMP . 663
METHOD FOR BLEEDING AIR FROM HST PUMP . 663
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP 663
TEST OUTLET PRESSURE OF SOLENOID VALVE 665
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 665
TEST TRAVEL DEVIATION . 670
METHOD FOR TESTING TRAVEL DEVIATION . 670
TEST BRAKE PERFORMANCE SIMPLY . 672
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY . 672
TEST AND ADJUST DECELERATION/BRAKE PEDAL 673
METHOD FOR TESTING DECELERATION/BRAKE PEDAL . 673
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL . 675
ADJUST PARKING BRAKE LEVER 677
METHOD FOR ADJUSTING PARKING BRAKE LEVER 677
MOVE MACHINE WHEN IT CANNOT TRAVEL 679
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 679
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT 681
UNDERCARRIAGE AND FRAME . 683
CHECK AND ADJUST IDLER CLEARANCE 683
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE . 683
TESTING SPROCKET WEAR . 684
METHOD FOR TESTING SPROCKET WEAR 684
TEST AND ADJUST TRACK TENSION . 685
METHOD FOR TESTING TRACK TENSION 685
METHOD FOR ADJUSTING TRACK TENSION 685
HYDRAULIC SYSTEM 687
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 687
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 687
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 688
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES . 688
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES . 689
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT . 691
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 691
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 692
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 693
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE 693
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP 695
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP 695
TEST COOLING FAN SPEED 696
METHOD FOR TESTING COOLING FAN SPEED 696
TEST COOLING FAN CIRCUIT OIL PRESSURE . 697
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE . 697
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 699
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER . 699
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER . 699
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 700
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 701
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 701
BLEED AIR FROM WORK EQUIPMENT CYLINDERS . 704
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS . 704
WORK EQUIPMENT 705
ADJUST WORK EQUIPMENT LOCK LEVER 705
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 705
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER 707
TEST PLAY OF BLADE ELECTRIC LEVER . 709
ADJUST PLAY OF BLADE ELECTRIC LEVER . 709
REPLACE UNIVERSAL JOINT . 710
ELECTRICAL SYSTEM . 717
SET AND OPERATE MACHINE MONITOR . 717
OPERATOR MODE . 721
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 721
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 721
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 722
CHECK FUNCTION OF SERVICE METER . 722
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 722
SERVICE MODE 725
OPERATE SERVICE MODE 725
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 726
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 733
ABNORMALITY RECORD MENU . 745
METHOD FOR CONFIRMING MAINTENANCE RECORD 749
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 750
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 754
DEFAULT MENU 756
DIAGNOSTIC TESTS MENU . 764
ADJUSTMENT MENU . 772
METHOD FOR PERFORMING NO-INJECTION CRANKING . 841
KOMTRAX SETTINGS MENU . 844
METHOD FOR DISPLAYING SERVICE MESSAGE . 846
START UP KOMTRAX SYSTEM . 848
STOP USING OF KOMTRAX SYSTEM 854
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 856
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED . 856
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 862
ADJUST REARVIEW CAMERA ANGLE 864
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 864
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 865
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 865
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 867
BATTERY DISCONNECT SWITCH . 868
TEST DIODES . 869
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 869
METHOD FOR TESTING DIODE USING ANALOG TESTER 869
ICT SYSTEM 870
TEST AND ADJUST ICT RELATED DEVICES . 870
SET AND OPERATE CONTROL BOX . 872
MACHINE CALIBRATION . 873
IMU SENSOR CALIBRATION 874
OPERATE MACHINE CALIBRATION STEP A 880
OPERATE MACHINE CALIBRATION STEP B 886
CALIBRATE GNSS ANTENNA (AUX) LOCATION . 892
OPERATE PITCH ROD CALIBRATION . 894
INPUT WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE 896
RESET CYLINDER STROKE END . 897
RESET LIFT CYLINDER STROKE END 897
RESET TILT CYLINDER STROKE END 898
RESET ANGLE CYLINDER STROKE END . 898
OPERATE MANUAL MACHINE CALIBRATION 899
CHECK AND ADJUST BLADE ELEVATION 901
CHECK BLADE ELEVATION . 901
ADJUST BLADE ELEVATION 901
TEST STROKE SENSOR FOR LIFT CYLINDER 904
TEST STROKE SENSOR FOR LIFT CYLINDER 904
TEST STROKE SENSOR FOR TILT CYLINDER 906
TEST STROKE SENSOR FOR TILT CYLINDER 906
TEST STROKE SENSOR FOR ANGLE CYLINDER . 908
TEST STROKE SENSOR FOR ANGLE CYLINDER . 908
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER 910
TEST RESET SENSOR FOR LIFT CYLINDER . 910
ADJUST RESET SENSOR FOR LIFT CYLINDER . 911
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED . 912
METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED . 912
ADJUST AFTER REPLACEMENT OF IMU SENSOR 915
ADJUST AFTER REPLACEMENT OF IMU SENSOR 915
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED 916
Pm CLINIC . 919
Pm CLINIC SERVICE . 919
Pm CLINIC CHECK SHEET: D61EXI-24 921
Pm CLINIC CHECK SHEET: D61EXI-24E0 928
Pm CLINIC CHECK SHEET: D61PXI-24 935
Pm CLINIC CHECK SHEET: D61PXI-24E0 942
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EXI-24 949
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EXI-24E0 952
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PXI-24 955
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PXI-24E0 958
40 TROUBLESHOOTING 961
CONTENTS 962
ABBREVIATION LIST . 974
RELATED INFORMATION ON TROUBLESHOOTING 980
GENERAL TROUBLESHOOTING POINTS 980
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 981
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 996
CHECKS BEFORE TROUBLESHOOTING . 998
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING .1000
WALK-AROUND CHECK .1000
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1002
CHECK FUEL LEVEL AND TYPE .1002
CHECK IMPURE INGREDIENT IN FUEL .1002
CHECK AdBule/DEF LEVEL AND TYPE .1003
CHECK FUEL PREFILTER 1003
CHECK MAIN FILTER .1005
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE .1006
CHECK COOLANT LEVEL (RESERVOIR TANK) 1007
CHECK CLOGGING OF AIR CLEANER .1008
CLEAN OUTER ELEMENT .1008
REPLACE ELEMENT .1011
CHECK HYDRAULIC OIL LEVEL .1011
CHECK HYDRAULIC OIL STRAINER 1012
CHECK HYDRAULIC FILTER 1015
CHECK OIL LEVEL IN FINAL DRIVE CASE .1016
BLEED AIR FROM FUEL SYSTEM 1017
BLEED AIR FROM HYDRAULIC SYSTEM .1017
METHOD FOR CHECKING ELECTRIC EQUIPMENT 1017
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM .1024
PROCEDURE FOR TROUBLESHOOTING .1031
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1034
CONNECTORS LIST AND LAYOUT 1036
CONNECTOR CONTACT IDENTIFICATION 1054
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .1094
FUSE LOCATION TABLE .1100
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) .1104
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) .1108
FAILURE CODES TABLE .1110
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1131
FAILURE CODE [6091NX] .1131
FAILURE CODE [989L00] .1133
FAILURE CODE [989M00] .1134
FAILURE CODE [989N00] .1135
FAILURE CODE [A1U0N3] .1136
FAILURE CODE [A1U0N4] .1138
FAILURE CODE [A900FR] .1140
FAILURE CODE [A900N6] .1141
FAILURE CODE [A900NY] .1142
FAILURE CODE [AA10NX] .1143
FAILURE CODE [AB00KE] .1145
FAILURE CODE [AQ10N3] .1147
FAILURE CODE [AS00N3] .1149
FAILURE CODE [AS00R2] .1151
FAILURE CODE [AS00R3] .1152
FAILURE CODE [AS00R4] .1153
FAILURE CODE [AS00R5] .1154
FAILURE CODE [AS00R6] .1155
FAILURE CODE [AS00ZK] .1156
FAILURE CODE [AS10KM] .1157
FAILURE CODE [AS10NR] .1158
FAILURE CODE [AS10NT] .1159
FAILURE CODE [B@BAZG] .1160
FAILURE CODE [B@BCNS] .1161
FAILURE CODE [B@BCQA] .1162
FAILURE CODE [B@BCZK] .1164
FAILURE CODE [B@CRNS] .1166
FAILURE CODE [B@CRZG] .1167
FAILURE CODE [CA115] 1168
FAILURE CODE [CA122] 1169
FAILURE CODE [CA123] 1171
FAILURE CODE [CA131] 1173
FAILURE CODE [CA132] 1175
FAILURE CODE [CA144] 1177
FAILURE CODE [CA145] 1179
FAILURE CODE [CA153] 1181
FAILURE CODE [CA154] 1184
FAILURE CODE [CA187] 1186
FAILURE CODE [CA221] 1188
FAILURE CODE [CA222] 1190
FAILURE CODE [CA227] 1192
FAILURE CODE [CA234] 1193
FAILURE CODE [CA238] 1194
FAILURE CODE [CA239] 1196
FAILURE CODE [CA249] 1198
FAILURE CODE [CA256] 1200
FAILURE CODE [CA271] 1202
FAILURE CODE [CA272] 1204
FAILURE CODE [CA322] 1206
FAILURE CODE [CA323] 1208
FAILURE CODE [CA324] 1210
FAILURE CODE [CA325] 1212
FAILURE CODE [CA331] 1214
FAILURE CODE [CA332] 1216
FAILURE CODE [CA343] 1218
FAILURE CODE [CA351] 1219
FAILURE CODE [CA352] 1220
FAILURE CODE [CA356] 1223
FAILURE CODE [CA357] 1225
FAILURE CODE [CA386] 1228
FAILURE CODE [CA428] 1229
FAILURE CODE [CA429] 1231
FAILURE CODE [CA435] 1233
FAILURE CODE [CA441] 1235
FAILURE CODE [CA442] 1237
FAILURE CODE [CA449] 1238
FAILURE CODE [CA451] 1239
FAILURE CODE [CA452] 1241
FAILURE CODE [CA488] 1243
FAILURE CODE [CA515] 1244
FAILURE CODE [CA516] 1246
FAILURE CODE [CA553] 1248
FAILURE CODE [CA555] 1249
FAILURE CODE [CA556] 1250
FAILURE CODE [CA559] 1251
FAILURE CODE [CA595] 1254
FAILURE CODE [CA687] 1255
FAILURE CODE [CA689] 1257
FAILURE CODE [CA691] 1260
FAILURE CODE [CA692] 1262
FAILURE CODE [CA697] 1264
FAILURE CODE [CA698] 1265
FAILURE CODE [CA731] 1266
FAILURE CODE [CA778] 1268
FAILURE CODE [CA1117] .1273
FAILURE CODE [CA1664] .1274
FAILURE CODE [CA1669] .1277
FAILURE CODE [CA1673] .1278
FAILURE CODE [CA1677] .1279
FAILURE CODE [CA1678] .1280
FAILURE CODE [CA1682] .1281
FAILURE CODE [CA1683] .1285
FAILURE CODE [CA1684] .1287
FAILURE CODE [CA1686] .1289
FAILURE CODE [CA1691] .1290
FAILURE CODE [CA1694] .1293
FAILURE CODE [CA1695] .1296
FAILURE CODE [CA1696] .1297
FAILURE CODE [CA1712] .1299
FAILURE CODE [CA1713] .1302
FAILURE CODE [CA1714] .1304
FAILURE CODE [CA1715] .1305
FAILURE CODE [CA1776] .1306
FAILURE CODE [CA1777] .1309
FAILURE CODE [CA1843] .1312
FAILURE CODE [CA1844] .1314
FAILURE CODE [CA1879] .1317
FAILURE CODE [CA1881] .1320
FAILURE CODE [CA1883] .1322
FAILURE CODE [CA1885] .1326
FAILURE CODE [CA1887] .1328
FAILURE CODE [CA1921] .1330
FAILURE CODE [CA1922] .1333
FAILURE CODE [CA1942] .1338
FAILURE CODE [CA1993] .1339
FAILURE CODE [CA2185] .1342
FAILURE CODE [CA2186] .1344
FAILURE CODE [CA2249] .1346
FAILURE CODE [CA2271] .1347
FAILURE CODE [CA2272] .1350
FAILURE CODE [CA2288] .1353
FAILURE CODE [CA2311] .1354
FAILURE CODE [CA2349] .1355
FAILURE CODE [CA2353] .1358
FAILURE CODE [CA2357] .1360
FAILURE CODE [CA2381] .1361
FAILURE CODE [CA2382] .1364
FAILURE CODE [CA2383] .1367
FAILURE CODE [CA2386] .1370
FAILURE CODE [CA2387] .1372
TROUBLESHOOTING FLOWCHART .1376
FAILURE CODE [CA2555] .1377
FAILURE CODE [CA2556] .1380
FAILURE CODE [CA2637] .1383
FAILURE CODE [CA2639] .1385
FAILURE CODE [CA2771] .1388
FAILURE CODE [CA2777] .1394
FAILURE CODE [CA2976] .1397
FAILURE CODE [CA3133] .1399
FAILURE CODE [CA3134] .1401
FAILURE CODE [CA3135] .1403
FAILURE CODE [CA3142] .1407
FAILURE CODE [CA3143] .1408
FAILURE CODE [CA3144] .1409
FAILURE CODE [CA3146] .1411
FAILURE CODE [CA3147] .1412
FAILURE CODE [CA3148] .1413
FAILURE CODE [CA3151] .1415
FAILURE CODE [CA3165] .1421
FAILURE CODE [CA3229] .1424
FAILURE CODE [CA3231] .1426
FAILURE CODE [CA3232] .1428
FAILURE CODE [CA3235] .1432
FAILURE CODE [CA3239] .1434
FAILURE CODE [CA3241] .1437
FAILURE CODE [CA3242] .1440
FAILURE CODE [CA3251] .1443
FAILURE CODE [CA3253] .1445
FAILURE CODE [CA3254] .1448
FAILURE CODE [CA3255] .1451
FAILURE CODE [CA3256] .1454
FAILURE CODE [CA3311] .1456
FAILURE CODE [CA3312] .1458
FAILURE CODE [CA3313] .1461
FAILURE CODE [CA3314] .1462
FAILURE CODE [CA3315] .1463
FAILURE CODE [CA3316] .1466
FAILURE CODE [CA3317] .1467
FAILURE CODE [CA3318] .1468
FAILURE CODE [CA3319] .1471
FAILURE CODE [CA3321] .1472
FAILURE CODE [CA3322] .1474
FAILURE CODE [CA3419] .1477
FAILURE CODE [CA3421] .1479
FAILURE CODE [CA3497] .1481
FAILURE CODE [CA3498] .1482
FAILURE CODE [CA3543] .1483
FAILURE CODE [CA3545] .1490
FAILURE CODE [CA3547] .1492
FAILURE CODE [CA3558] .1493
FAILURE CODE [CA3559] .1495
FAILURE CODE [CA3562] .1497
FAILURE CODE [CA3563] .1499
FAILURE CODE [CA3567] .1502
FAILURE CODE [CA3568] .1506
FAILURE CODE [CA3571] .1512
FAILURE CODE [CA3572] .1514
FAILURE CODE [CA3574] .1516
FAILURE CODE [CA3575] .1519
FAILURE CODE [CA3577] .1521
FAILURE CODE [CA3578] .1523
FAILURE CODE [CA3582] .1525
FAILURE CODE [CA3583] .1533
FAILURE CODE [CA3596] .1535
FAILURE CODE [CA3649] .1538
FAILURE CODE [CA3681] .1540
FAILURE CODE [CA3682] .1545
FAILURE CODE [CA3713] .1551
FAILURE CODE [CA3717] .1554
FAILURE CODE [CA3718] .1555
FAILURE CODE [CA3725] .1556
FAILURE CODE [CA3741] .1559
FAILURE CODE [CA3748] .1560
FAILURE CODE [CA3751] .1562
FAILURE CODE [CA3755] .1564
FAILURE CODE [CA3866] .1566
FAILURE CODE [CA3867] .1570
FAILURE CODE [CA3868] .1573
FAILURE CODE [CA3899] .1577
FAILURE CODE [CA3911] .1579
FAILURE CODE [CA3912] .1583
FAILURE CODE [CA3932] .1585
FAILURE CODE [CA3933] .1587
FAILURE CODE [CA3934] .1589
FAILURE CODE [CA3935] .1592
FAILURE CODE [CA3936] .1594
FAILURE CODE [CA4151] .1596
FAILURE CODE [CA4152] .1600
FAILURE CODE [CA4155] .1604
FAILURE CODE [CA4156] .1607
FAILURE CODE [CA4157] .1610
FAILURE CODE [CA4158] .1612
FAILURE CODE [CA4159] .1613
FAILURE CODE [CA4161] .1614
FAILURE CODE [CA4162] .1617
FAILURE CODE [CA4163] .1620
FAILURE CODE [CA4164] .1622
FAILURE CODE [CA4165] .1624
FAILURE CODE [CA4166] .1626
FAILURE CODE [CA4168] .1628
FAILURE CODE [CA4169] .1631
FAILURE CODE [CA4171] .1633
FAILURE CODE [CA4249] .1636
FAILURE CODE [CA4251] .1638
FAILURE CODE [CA4259] .1640
FAILURE CODE [CA4261] .1643
FAILURE CODE [CA4277] .1646
FAILURE CODE [CA4281] .1650
FAILURE CODE [CA4459] .1653
FAILURE CODE [CA4461] .1656
FAILURE CODE [CA4658] .1659
FAILURE CODE [CA4731] .1663
FAILURE CODE [CA4732] .1664
FAILURE CODE [CA4739] .1665
FAILURE CODE [CA4768] .1666
FAILURE CODE [CA4769] .1668
FAILURE CODE [CA4842] .1671
FAILURE CODE [CA4952] .1675
FAILURE CODE [CA5115] .1677
FAILURE CODE [CA5383] .1680
FAILURE CODE [D130KA] .1682
FAILURE CODE [D130KB] .1685
FAILURE CODE [D130KY] .1687
FAILURE CODE [D19DKA] .1689
FAILURE CODE [D19DKB] .1691
FAILURE CODE [D19DKY] .1693
FAILURE CODE [D19JKZ] .1696
FAILURE CODE [D811MC] .1699
FAILURE CODE [D862KA] .1700
FAILURE CODE [D8G1KT] .1702
FAILURE CODE [D8G6KT] .1703
FAILURE CODE [D8ALKA] .1704
FAILURE CODE [D8ALKB] .1708
FAILURE CODE [D8AQKR] .1711
FAILURE CODE [DAF0MB] .1713
FAILURE CODE [DAF0MC] .1714
FAILURE CODE [DAF8KB] .1715
FAILURE CODE [DAF9KQ] .1717
FAILURE CODE [DAFGMC] .1718
FAILURE CODE [DAFLKA] .1719
FAILURE CODE [DAFLKB] .1721
FAILURE CODE [DAFQKR] .1723
FAILURE CODE [DAJ000] .1724
FAILURE CODE [DAJ0KQ] .1725
FAILURE CODE [DAJ0KT] .1726
FAILURE CODE [DAJ0MC] .1727
FAILURE CODE [DAJ1KK] .1728
FAILURE CODE [DAJ2KK] .1730
FAILURE CODE [DAJ5KK] .1732
FAILURE CODE [DAJ6KK] .1735
FAILURE CODE [DAJLKA] .1737
FAILURE CODE [DAJLKB] .1739
FAILURE CODE [DAJPMA] .1741
FAILURE CODE [DAJQKR] .1742
FAILURE CODE [DAJRKR] .1743
FAILURE CODE [DB2QKR] .1744
FAILURE CODE [DB2RKR] .1751
FAILURE CODE [DBR0KT] .1756
FAILURE CODE [DBR0MC] .1757
FAILURE CODE [DBR1KK] .1758
FAILURE CODE [DBR2KK] .1761
FAILURE CODE [DBR5KK] .1764
FAILURE CODE [DBRLKA] .1766
FAILURE CODE [DBRLKB] .1768
FAILURE CODE [DBRPMA] .1770
FAILURE CODE [DBRQKR] .1771
FAILURE CODE [DBRRKR] .1773
FAILURE CODE [DBU0KR] .1774
FAILURE CODE [DBUSKR] .1775
FAILURE CODE [DBUTKA] .1780
FAILURE CODE [DBUTKN] .1781
FAILURE CODE [DBUTMA] .1783
FAILURE CODE [DBUUKA] .1784
FAILURE CODE [DBUUKN] .1786
FAILURE CODE [DD12KA] .1788
FAILURE CODE [DD12KB] .1790
FAILURE CODE [DD13KA] .1792
FAILURE CODE [DD13KB] .1794
FAILURE CODE [DD14KA] .1796
FAILURE CODE [DD14KB] .1798
FAILURE CODE [DDKAKA] .1800
FAILURE CODE [DDKAKB] .1802
FAILURE CODE [DDKFL4] .1804
FAILURE CODE [DDKGL4] .1806
FAILURE CODE [DDKHKA] .1808
FAILURE CODE [DDKHKB] .1810
FAILURE CODE [DDKQKA] .1812
FAILURE CODE [DDKQKB] .1814
FAILURE CODE [DDKRKA] .1816
FAILURE CODE [DDKRKB] .1818
FAILURE CODE [DDKSKA] .1820
FAILURE CODE [DDKSKB] .1822
FAILURE CODE [DDNLKA] .1824
FAILURE CODE [DDNLKB] .1826
FAILURE CODE [DDP6KA] .1828
FAILURE CODE [DDP6KB] .1831
FAILURE CODE [DDP6MA] .1833
FAILURE CODE [DDU1FS] .1835
FAILURE CODE [DDU1KA] .1837
FAILURE CODE [DDU1KY] .1840
FAILURE CODE [DFA4KX] .1842
FAILURE CODE [DFA4KZ] .1843
FAILURE CODE [DFA4L8] .1844
FAILURE CODE [DFA5KA] .1845
FAILURE CODE [DFA5KB] .1848
FAILURE CODE [DFA6KA] .1851
FAILURE CODE [DFA6KB] .1854
FAILURE CODE [DFA7KX] .1857
FAILURE CODE [DFA7KZ] .1858
FAILURE CODE [DFA7L8] .1859
FAILURE CODE [DFA8KA] .1860
FAILURE CODE [DFA8KB] .1863
FAILURE CODE [DFA9KA] .1866
FAILURE CODE [DFA9KB] .1869
FAILURE CODE [DGS1KA] .1872
FAILURE CODE [DGS1KX] .1875
FAILURE CODE [DH21KA] .1876
FAILURE CODE [DH21KB] .1878
FAILURE CODE [DHA4KA] .1880
FAILURE CODE [DHAAMA] .1882
FAILURE CODE [DHACMA] .1884
FAILURE CODE [DHH7KA] .1886
FAILURE CODE [DHH7KB] .1889
FAILURE CODE [DHH8KA] .1891
FAILURE CODE [DHH8KB] .1894
FAILURE CODE [DHH9KA] .1896
FAILURE CODE [DHH9KB] .1899
FAILURE CODE [DHHAKA] .1901
FAILURE CODE [DHHAKB] .1904
FAILURE CODE [DHRUKA] .1906
FAILURE CODE [DHRUKB] .1908
FAILURE CODE [DHRVKA] .1910
FAILURE CODE [DHRVKB] .1912
FAILURE CODE [DK30KA] .1914
FAILURE CODE [DK30KB] .1917
FAILURE CODE [DK30KX] .1919
FAILURE CODE [DK30KZ] .1920
FAILURE CODE [DK30L8] .1921
FAILURE CODE [DK31KA] .1922
FAILURE CODE [DK31KB] .1925
FAILURE CODE [DK40KA] .1927
FAILURE CODE [DK40KB] .1930
FAILURE CODE [DK55KX] .1932
FAILURE CODE [DK55KZ] .1933
FAILURE CODE [DK55L8] .1934
FAILURE CODE [DK56KA] .1935
FAILURE CODE [DK56KB] .1938
FAILURE CODE [DK57KA] .1940
FAILURE CODE [DK57KB] .1943
FAILURE CODE [DK80KA] .1945
FAILURE CODE [DK80KR] .1948
FAILURE CODE [DK80KT] .1953
FAILURE CODE [DKS0L8] .1956
FAILURE CODE [DKS1KA] .1957
FAILURE CODE [DKS1KB] .1959
FAILURE CODE [DKS2KA] .1961
FAILURE CODE [DKS2KB] .1963
FAILURE CODE [DKS3KA] .1965
FAILURE CODE [DKS3KB] .1967
FAILURE CODE [DKS3MB] .1969
FAILURE CODE [DKS4L8] .1971
FAILURE CODE [DKS5KA] .1972
FAILURE CODE [DKS5KB] .1974
FAILURE CODE [DKS6KA] .1976
FAILURE CODE [DKS6KB] .1978
FAILURE CODE [DKS7MB] .1980
FAILURE CODE [DKSCL8] .1981
FAILURE CODE [DKSDKA] .1982
FAILURE CODE [DKSDKB] .1984
FAILURE CODE [DKSEKA] .1986
FAILURE CODE [DKSEKB] .1988
FAILURE CODE [DKSFMB] .1990
FAILURE CODE [DLM0KX] .1991
FAILURE CODE [DLM0MA] .1992
FAILURE CODE [DLM1KA] .1993
FAILURE CODE [DLM1KB] .1995
FAILURE CODE [DLM1MA] .1997
FAILURE CODE [DLM2KA] .1998
FAILURE CODE [DLM2KB] .2000
FAILURE CODE [DLM2MA] .2002
FAILURE CODE [DLM3KA] .2003
FAILURE CODE [DLM3KB] .2005
FAILURE CODE [DLM3MB] .2007
FAILURE CODE [DN21FS] .2008
FAILURE CODE [DR21KX] .2010
FAILURE CODE [DR31KX] .2011
FAILURE CODE [DV20KB] .2012
FAILURE CODE [DW4BKA] .2014
FAILURE CODE [DW4BKB] .2016
FAILURE CODE [DW4BKY] .2018
FAILURE CODE [DW7BKA] .2020
FAILURE CODE [DW7BKB] .2022
FAILURE CODE [DW7EKA] .2024
FAILURE CODE [DW7EKB] .2026
FAILURE CODE [DW7EKY] .2028
FAILURE CODE [DWN5KA] .2030
FAILURE CODE [DWN5KB] .2032
FAILURE CODE [DWN5KY] .2034
FAILURE CODE [DXA4KA] .2036
FAILURE CODE [DXA4KB] .2038
FAILURE CODE [DXA4KY] .2040
FAILURE CODE [DXA5KA] .2042
FAILURE CODE [DXA5KB] .2044
FAILURE CODE [DXA5KY] .2046
FAILURE CODE [DXA6KA] .2048
FAILURE CODE [DXA6KB] .2050
FAILURE CODE [DXA6KY] .2052
FAILURE CODE [DXA7KA] .2054
FAILURE CODE [DXA7KB] .2056
FAILURE CODE [DXA7KY] .2058
FAILURE CODE [DXHRKA] .2060
FAILURE CODE [DXHRKB] .2062
FAILURE CODE [DXHRKY] .2064
FAILURE CODE [DXHSKA] .2066
FAILURE CODE [DXHSKB] .2068
FAILURE CODE [DXHSKY] .2070
FAILURE CODE [DXHTKA] .2072
FAILURE CODE [DXHTKB] .2074
FAILURE CODE [DXHTKY] .2076
FAILURE CODE [DXHUKA] .2078
FAILURE CODE [DXHUKB] .2080
FAILURE CODE [DXHUKY] .2082
FAILURE CODE [DXJ4KA] .2084
FAILURE CODE [DXJ4KB] .2086
FAILURE CODE [DXJCKA] .2088
FAILURE CODE [DXJCKB] .2090
FAILURE CODE [DXJCKY] .2092
FAILURE CODE [DXJDKA] .2094
FAILURE CODE [DXJDKB] .2096
FAILURE CODE [DXJDKY] .2098
FAILURE CODE [DXK1KA] .2100
FAILURE CODE [DXK1KB] .2102
FAILURE CODE [DXK1KY] .2104
FAILURE CODE [DXK2KA] .2106
FAILURE CODE [DXK2KB] .2108
FAILURE CODE [DXK2KY] .2110
FAILURE CODE [F313KA] .2112
FAILURE CODE [F313KB] .2113
FAILURE CODE [F318KB] .2114
FAILURE CODE [F318KY] .2115
FAILURE CODE [F7A0KQ] .2116
FAILURE CODE [F7A0KT] .2117
FAILURE CODE [F7A1KK] .2118
FAILURE CODE [F7ALKB] .2121
FAILURE CODE [F7AQKR] .2123
FAILURE CODE [F7ASKA] .2124
FAILURE CODE [FE0AKA] .2126
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .2128
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .2128
MANUAL PREHEATING SYSTEM DOES NOT WORK 2135
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .2138
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .2140
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .2142
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 2146
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2147
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2148
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2149
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2150
HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2151
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2152
HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2153
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2154
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2155
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .2158
OPERATION MODE DOES NOT CHANGE 2159
OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 2160
MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 2161
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2162
SERVICE MODE CANNOT BE SELECTED .2163
WORK EQUIPMENT DOES NOT OPERATE .2164
FOOT HEATER DOES NOT OPERATE 2166
HORN DOES NOT SOUND .2172
HORN DOES NOT STOP SOUNDING .2174
BACKUP ALARM DOES NOT SOUND .2175
BACKUP ALARM DOES NOT STOP SOUNDING .2176
HEADLAMP DOES NOT LIGHT UP 2177
REAR LAMP DOES NOT LIGHT UP .2181
ALL WIPERS DO NOT OPERATE .2184
FRONT WIPER DOES NOT OPERATE 2186
REAR WIPER DOES NOT OPERATE .2188
LEFT DOOR WIPER DOES NOT OPERATE 2190
RIGHT DOOR WIPER DOES NOT OPERATE .2194
FRONT WASHER DOES NOT OPERATE .2198
REAR WASHER DOES NOT OPERATE 2200
LEFT DOOR WASHER DOES NOT OPERATE .2202
RIGHT DOOR WASHER DOES NOT OPERATE 2204
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2206
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link .] 2207
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites .] 2209
CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected !] and [Komatsu Machine Trouble] .2210
CONTROL BOX SHOWS THE MESSAGE [Komatsu Machine Trouble] .2211
CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize .] .2212
CONTROL BOX DISPLAYS THE MESSAGE [System initializing] 2213
CONTROL BOX DISPLAYS THE MESSAGE [Initializing .] 2214
CONTROL BOX DISPLAYS THE MESSAGE [Connecting to GPS .] .2215
ELEVATION CONTROL KEY ON CONTROL BOX DISPLAYS THE MESSAGE [Low precisions .] .2216
CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing] .2217
CONTROL BOX DISPLAYS THE MESSAGE [Out of design area .] 2218
CONTROL BOX DISPLAYS THE MESSAGE [No GPS localization .] .2219
CONTROL BOX DISPLAYS THE MESSAGE [Loading Design Surface data .] .2220
CONTROL BOX DISPLAYS THE MESSAGE [Design Surface data invalid] 2221
CONTROL BOX DISPLAYS THE MESSAGE [Starting switch is OFF] .2222
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites .] and [Komatsu Machine Trouble] 2224
CONTROL BOX CANNOT BE TURNED ON .2225
CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN .2227
CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE 2228
CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE .2229
CONTROL BOX TOUCH PANEL DOES NOT RESPOND 2230
CONTROL BOX TOUCH PANEL IS INACCURATE .2231
CYLINDER STROKE RESET INDICATION DOES NOT GO OUT 2232
AUTO OR STRIKETHROUGH IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO OR STRIKETHROUGH GOES OUT) 2233
WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE .2235
BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2236
BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2237
BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS) .2238
FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) 2239
FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH) .2240
FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION) 2241
MACHINE CANNOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS) .2243
MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED 2244
BLADE TILT ANGLE DOES NOT CORRESPOND WITH DESIGN SURFACE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED .2245
BLADE TILTS WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED 2247
EVEN AFTER LIFT LAYER CONTROL IS ACTIVATED, MEASURED LIFT LAYER TERRAIN SHAPE DOES NOT CORRESPOND WITH THE ACTUAL TERRAIN .2249
THE SURFACE CREATED WITH QUICK SURFACE CREATION FUNCTION IS DIFFERENT FROM THE ONE IN MACHINE FRONT DIRECTION, BLADE EDGE POSITION 2251
MACHINE DOES NOT TRAVEL STRAIGHT WHILE TILT STEERING CONTROL IS ACTIVATED .2252
CONTROL BOX KEEPS DISPLAYING PROGRESS BAR IN MACHINE MANUAL CAL SCREEN 2253
ENGINE HUNTING OCCURS WHEN LOWERING THE BLADE WHILE GROUND LINE ASSIST IS ACTIVATED .2254
[LASER RECEIVER ERROR (RED)] ICON IS SHOWN ON CONTROL BOX (2D LASER MACHINE CONTROL) 2255
[SYSTEM ERROR (RED)] ICON IS SHOWN ON CONTROL BOX (2D LASER MACHINE CONTROL) 2259
[AUTO (GREEN)] IS NOT SHOWN ON CONTROL BOX (2D LASER MACHINE CONTROL) .2260
FINISHED SURFACE IS INACCURATE (2D LASER MACHINE CONTROL) .2261
GROUND SURFACE BECOMES ROUGH IN LEVELING WORK (2D LASER MACHINE CONTROL) 2262
CURRENT SLOPE VALUE ON CONTROL BOX IS DIFFERENT FROM ACTUAL VALUE (2D LASER MACHINE CONTROL) 2263
AUTOMATIC CONTROL CANNOT BE DONE IF YOU CHANGE APPLICATION (2D LASER MACHINE CONTROL) .2264
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .2265
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .2265
FAILURE MODE AND CAUSE TABLE 2266
NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) 2272
EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE) .2274
EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION) .2276
TRAVEL SPEED OR POWER IS LOW 2278
SPEED RANGE DOES NOT CHANGE .2280
SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS 2281
MACHINE DEVIATES LARGELY 2282
MACHINE DRIFT ON A SLOPE IS LARGE .2285
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2287
UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 2289
HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 2291
ALL WORK EQUIPMENT DO NOT OPERATE .2293
ALL WORK EQUIPMENTS SPEED OR POWER IS LOW .2295
BLADE LIFT SPEED OR POWER IS LOW 2296
BLADE TILT SPEED OR POWER IS LOW 2298
BLADE ANGLE SPEED OR POWER IS LOW .2299
TIME LAG OF BLADE LIFT IS LARGE .2300
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 2301
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 2302
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE .2303
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2304
UNUSUAL NOISE IS HEARD FROM AROUND FAN 2306
TROUBLESHOOTING OF ENGINE (S-MODE) 2307
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2307
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2308
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2309
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2310
ENGINE STARTABILITY IS POOR .2312
ENGINE DOES NOT PICK UP SMOOTHLY 2314
ENGINE STOPS DURING OPERATION .2316
ENGINE RUNS ROUGH OR IS UNSTABLE 2318
ENGINE LACKS POWER 2319
KDPF GETS CLOGGED IN A SHORT TIME .2321
ENGINE OIL CONSUMPTION IS EXCESSIVE .2323
OIL BECOMES CONTAMINATED QUICKLY 2324
FUEL CONSUMPTION IS EXCESSIVE .2325
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .2326
OIL PRESSURE DROPS 2327
FUEL MIXES INTO ENGINE OIL 2329
WATER MIXES INTO ENGINE OIL (MILKY) .2330
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2331
UNUSUAL NOISE IS HEARD 2332
VIBRATION IS EXCESSIVE 2333
AIR CANNOT BE BLED FROM FUEL CIRCUIT 2334
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2335
ACTIVE REGENERATION TAKES TIME 2337
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .2338
AdBlue/DEF CONSUMPTION IS EXCESSIVE .2339
THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2341
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) .2342
50 DISASSEMBLY AND ASSEMBLY .2343
CONTENTS 2344
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2350
HOW TO READ THIS MANUAL .2350
COATING MATERIALS LIST 2352
SPECIAL TOOLS LIST 2356
SKETCHES OF SPECIAL TOOLS .2378
ENGINE AND COOLING SYSTEM .2391
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2391
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2392
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2397
REMOVE AND INSTALL INJECTOR ASSEMBLY 2404
METHOD FOR REMOVING INJECTOR ASSEMBLY .2404
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2411
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2421
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2421
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2433
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2451
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2451
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2452
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2454
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2454
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2456
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2459
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY .2459
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY .2461
REMOVE AND INSTALL ALTERNATOR BELT 2463
METHOD FOR REMOVING ALTERNATOR BELT .2463
METHOD FOR INSTALLING ALTERNATOR BELT .2464
REMOVE AND INSTALL AUTOMATIC TENSIONER 2466
METHOD FOR REMOVING AUTOMATIC TENSIONER .2466
METHOD FOR INSTALLING AUTOMATIC TENSIONER .2466
REMOVE AND INSTALL RADIATOR ASSEMBLY 2467
METHOD FOR REMOVING RADIATOR ASSEMBLY .2467
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2470
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2474
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2474
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2477
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2480
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2480
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2483
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY .2487
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2487
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2490
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2494
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2494
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2497
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY 2501
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY .2501
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY .2510
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2521
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2521
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2522
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2524
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2524
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2526
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2529
REMOVE ENGINE HOOD ASSEMBLY .2529
INSTALL ENGINE HOOD ASSEMBLY 2532
REMOVE AND INSTALL KDPF ASSEMBLY 2536
METHOD FOR REMOVING KDPF ASSEMBLY .2537
METHOD FOR INSTALLING KDPF ASSEMBLY .2540
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2543
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2543
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2546
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2553
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2554
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2560
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2567
REMOVE FUEL TANK ASSEMBLY .2567
INSTALL FUEL TANK ASSEMBLY 2573
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2580
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2580
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2586
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2592
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2592
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2593
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2596
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2596
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2597
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2604
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2604
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2605
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2606
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2606
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2607
REMOVE AND INSTALL SCR ASSEMBLY .2610
METHOD FOR REMOVING SCR ASSEMBLY 2610
METHOD FOR INSTALLING SCR ASSEMBLY 2612
REMOVE AND INSTALL KCCV ASSEMBLY 2616
METHOD FOR REMOVING KCCV ASSEMBLY .2616
METHOD FOR INSTALLING KCCV ASSEMBLY .2618
REMOVE AND INSTALL VGT ASSEMBLY .2620
METHOD FOR REMOVING VGT ASSEMBLY 2620
METHOD FOR INSTALLING VGT ASSEMBLY 2622
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2625
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2626
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2628
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2632
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2632
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2635
REMOVE AND INSTALL AdBlue/DEF PUMP 2639
METHOD FOR REMOVING AdBlue/DEF PUMP .2639
METHOD FOR INSTALLING AdBlue/DEF PUMP .2642
REMOVE AND INSTALL AdBlue/DEF HOSE 2645
METHOD FOR REMOVING AdBlue/DEF HOSE .2645
METHOD FOR INSTALLING AdBlue/DEF HOSE .2649
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2655
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2655
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2657
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2660
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2660
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2661
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2663
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2663
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2667
POWER TRAIN .2671
REMOVE AND INSTALL DAMPER ASSEMBLY 2671
METHOD FOR REMOVING DAMPER ASSEMBLY .2671
METHOD FOR INSTALLING DAMPER ASSEMBLY .2672
REMOVE AND INSTALL HST PUMP ASSEMBLY 2674
METHOD FOR REMOVING HST PUMP ASSEMBLY .2674
METHOD FOR INSTALLING HST PUMP ASSEMBLY .2676
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY .2678
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY 2678
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY 2681
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2684
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2685
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2690
UNDERCARRIAGE AND FRAME .2699
REMOVE AND INSTALL TRACK FRAME ASSEMBLY .2699
REMOVE TRACK FRAME ASSEMBLY .2699
INSTALL TRACK FRAME ASSEMBLY 2704
REMOVE AND INSTALL IDLER ASSEMBLY .2709
METHOD FOR REMOVING IDLER ASSEMBLY 2709
METHOD FOR INSTALLING IDLER ASSEMBLY 2711
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2713
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2713
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2715
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY .2720
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2720
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2721
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY .2722
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY 2722
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY 2725
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2728
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY .2728
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY .2729
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2732
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2732
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2734
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2738
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY .2738
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY .2739
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2741
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2741
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2742
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY .2745
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2745
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2746
SEPARATE AND CONNECT TRACK ASSEMBLY .2748
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY 2748
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) .2749
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) .2750
METHOD FOR CONNECTING TRACK ASSEMBLY 2751
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY .2753
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2753
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2753
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY .2755
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY .2755
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2760
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY .2773
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .2774
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2775
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2790
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2791
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2792
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2799
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2800
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2802
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY .2806
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 2806
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 2808
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS 2811
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS .2811
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS .2811
REMOVE AND INSTALL SEGMENT TEETH 2813
METHOD FOR REMOVING SEGMENT TEETH .2813
METHOD FOR INSTALLING SEGMENT TEETH .2814
HYDRAULIC SYSTEM 2815
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2815
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2816
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2820
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2825
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2825
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2830
WORK EQUIPMENT 2835
REMOVE AND INSTALL BLADE ASSEMBLY .2835
METHOD FOR REMOVING BLADE ASSEMBLY 2835
METHOD FOR INSTALLING BLADE ASSEMBLY 2837
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2841
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2841
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2845
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2848
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY .2848
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY .2850
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2853
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2854
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY .2858
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2866
METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY .2866
METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY .2869
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2874
METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2875
METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY .2878
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY .2883
METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2883
METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2886
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY .2889
METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY .2890
METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2893
REMOVE AND INSTALL U-FRAME ASSEMBLY .2899
METHOD FOR REMOVING U-FRAME ASSEMBLY 2899
METHOD FOR INSTALLING U-FRAME ASSEMBLY 2902
CAB AND ITS ATTACHMENTS .2905
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 2905
REMOVE OPERATOR CAB ASSEMBLY 2905
INSTALL OPERATOR CAB ASSEMBLY .2914
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) .2925
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2927
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2927
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2933
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2933
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2939
REMOVE AND INSTALL OPERATOR’S SEAT 2946
METHOD FOR REMOVING OPERATOR’S SEAT .2946
METHOD FOR INSTALLING OPERATOR’S SEAT .2947
REMOVE AND INSTALL SEAT BELT 2948
METHOD FOR REMOVING SEAT BELT .2948
METHOD FOR INSTALLING SEAT BELT .2948
REMOVE AND INSTALL FOOT HEATER ASSEMBLY .2950
METHOD FOR REMOVING FOOT HEATER ASSEMBLY 2950
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY 2952
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY .2955
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY .2955
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY 2956
ELECTRICAL SYSTEM .2957
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2957
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2957
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2959
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 2962
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY .2962
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY .2963
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2964
REMOVE MACHINE MONITOR ASSEMBLY .2964
INSTALL MACHINE MONITOR ASSEMBLY 2965
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2967
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2967
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2969
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2970
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2970
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2972
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2974
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2974
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2975
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2977
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY .2977
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2978
REMOVE AND INSTALL NAVIGATION CONTROLLER 2979
REMOVE NAVIGATION CONTROLLER 2980
INSTALL NAVIGATION CONTROLLER .2984
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY .2989
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY 2989
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY 2989
REMOVE AND INSTALL CONTROL BOX 2991
METHOD FOR REMOVING CONTROL BOX .2991
METHOD FOR INSTALLING CONTROL BOX .2992
REMOVE AND INSTALL GNSS RECEIVER 2993
REMOVE GNSS RECEIVER 2994
INSTALL GNSS RECEIVER .2994
REMOVE AND INSTALL GNSS ANTENNA .2996
REMOVE GNSS ANTENNA .2997
INSTALL GNSS ANTENNA 3001
REMOVE AND INSTALL IMU SENSOR .3006
REMOVE IMU SENSOR .3006
INSTALL IMU SENSOR 3008
REMOVE AND INSTALL COMMUNICATION TERMINAL .3010
REMOVE COMMUNICATION TERMINAL .3010
INSTALL COMMUNICATION TERMINAL 3013
REMOVE AND INSTALL COMMUNICATION ANTENNA 3016
REMOVE COMMUNICATION ANTENNA 3017
INSTALL COMMUNICATION ANTENNA .3019
60 MAINTENANCE STANDARD .3023
CONTENTS 3024
ABBREVIATION LIST .3026
ENGINE AND COOLING SYSTEM .3032
MAINTENANCE STANDARD OF ENGINE MOUNT 3032
MAINTENANCE STANDARD OF DAMPER 3033
MAINTENANCE STANDARD OF COOLING SYSTEM 3034
MAINTENANCE STANDARD OF COOLING FAN MOTOR .3036
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP .3038
POWER TRAIN .3039
MAINTENANCE STANDARD OF HST PUMP 3039
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP .3040
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP .3041
MAINTENANCE STANDARD OF HST CHARGE PUMP .3042
MAINTENANCE STANDARD OF HST MOTOR .3044
MAINTENANCE STANDARD OF FINAL DRIVE .3045
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE .3047
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 3048
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE .3050
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 3051
UNDERCARRIAGE AND FRAME .3053
MAINTENANCE STANDARD OF SUSPENSION 3053
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .3055
MAINTENANCE STANDARD OF IDLER .3057
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) .3059
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) .3060
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) .3061
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) .3062
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE .3063
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE .3064
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 3065
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 3067
MAINTENANCE STANDARD OF SINGLE SHOE .3069
MAINTENANCE STANDARD OF SWAMP SHOE 3070
HYDRAULIC SYSTEM 3071
MAINTENANCE STANDARD OF HYDRAULIC TANK 3071
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP .3072
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP 3073
MAINTENANCE STANDARD OF CONTROL VALVE .3075
MAINTENANCE STANDARD OF RIPPER PPC VALVE 3082
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID 3084
MAINTENANCE STANDARD OF EPC VALVE .3085
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE .3086
MAINTENANCE STANDARD OF QUICK DROP VALVE 3087
WORK EQUIPMENT 3089
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 3089
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 3092
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER .3093
MAINTENANCE STANDARD OF BLADE TILT CYLINDER .3094
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER 3095
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 3096
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 3098
CAB AND ITS ATTACHMENTS .3099
MAINTENANCE STANDARD OF CAB MOUNT .3099
ELECTRICAL SYSTEM .3100
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER .3100
80 APPENDIX .3101
CONTENTS 3102
ABBREVIATION LIST .3103
AIR CONDITIONER SYSTEM 3109
PRECAUTIONS FOR REFRIGERANT .3109
AIR CONDITIONER COMPONENT .3110
SPECIFICATIONS OF AIR CONDITIONER .3113
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .3114
OUTLINE OF REFRIGERATION CYCLE 3115
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .3117
AIR CONDITIONER UNIT 3117
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .3117
FUNCTION OF AIR CONDITIONER UNIT 3118
COMPONENT PARTS OF AIR CONDITIONER UNIT .3119
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3119
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .3119
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT 3119
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3120
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3120
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3120
FUNCTION OF DUAL PRESSURE SWITCH 3121
FUNCTION OF PRESSURE SWITCH .3121
COMPRESSOR 3122
STRUCTURE OF COMPRESSOR .3122
SPECIFICATIONS OF COMPRESSOR 3122
FUNCTION OF COMPRESSOR 3122
CONDENSER .3123
STRUCTURE OF CONDENSER 3123
SPECIFICATIONS OF CONDENSER .3123
FUNCTION OF CONDENSER .3124
RECEIVER DRIER 3125
STRUCTURE OF RECEIVER DRIER .3125
SPECIFICATIONS OF RECEIVER DRIER 3125
FUNCTION OF RECEIVER DRIER 3125
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .3127
CIRCUIT DIAGRAM OF AIR CONDITIONER 3130
AIR CONDITIONER SYSTEM DIAGRAM 3131
CONTROL FUNCTION OF AIR CONDITIONER .3132
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .3133
TEST RELAYS .3137
METHOD FOR TESTING RELAYS .3137
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3139
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3140
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3143
TROUBLESHOOTING FOR CONDENSER FAN .3145
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3148
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3152
TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 3155
TROUBLESHOOTING USING GAUGE PRESSURE 3159
CONNECTION OF SERVICE TOOL 3161
METHOD FOR CONNECTING SERVICE TOOL 3161
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3162
HANDLE COMPRESSOR OIL .3164
90 CIRCUIT DIAGRAMS .3167
CONTENTS 3168
HYDRAULIC CIRCUIT DIAGRAM .3169
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3169
HYDRAULIC CIRCUIT DIAGRAM .3173
ELECTRICAL CIRCUIT DIAGRAM 3175
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3175
ELECTRICAL CIRCUIT DIAGRAM (1/16) .3179
ELECTRICAL CIRCUIT DIAGRAM (2/16) .3181
ELECTRICAL CIRCUIT DIAGRAM (3/16) .3183
ELECTRICAL CIRCUIT DIAGRAM (4/16) .3185
ELECTRICAL CIRCUIT DIAGRAM (5/16) .3187
ELECTRICAL CIRCUIT DIAGRAM (6/16) .3189
ELECTRICAL CIRCUIT DIAGRAM (7/16) .3191
ELECTRICAL CIRCUIT DIAGRAM (8/16) .3193
ELECTRICAL CIRCUIT DIAGRAM (9/16) .3195
ELECTRICAL CIRCUIT DIAGRAM (10/16) 3197
ELECTRICAL CIRCUIT DIAGRAM (11/16) 3199
ELECTRICAL CIRCUIT DIAGRAM (12/16) 3201
ELECTRICAL CIRCUIT DIAGRAM (13/16) 3203
ELECTRICAL CIRCUIT DIAGRAM (14/16) 3205
ELECTRICAL CIRCUIT DIAGRAM (15/16) 3207
ELECTRICAL CIRCUIT DIAGRAM (16/16) 3209
ELECTRICAL CIRCUIT DIAGRAM (2D LASER MACHINE CONTROL) .3211
INDEX 3213

DESCRIPTION:

Komatsu D61EXi-24,D61EXi-24E0,D61PXi-24,D61PXi-24E0 Bulldozer Shop Manual KEBM685605 – PDF DOWNLOAD

SERIAL NUMBERS

• D61EXi-B65001 and up
• D61PXi-B65001 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.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 30/12/24