Komatsu Engine D61EX-24 D61PX-24 Series Shop Manual SEN06577-06 PDF

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Komatsu Engine D61EX-24 D61PX-24 Series Shop Manual SEN06577-06 – PDF DOWNLOAD

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Komatsu Engine D61EX-24 D61PX-24 Series Shop Manual SEN06577-06 PDF – DOWNLOAD

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Komatsu Engine D61EX-24 D61PX-24 Series Shop Manual SEN06577-06 PDF – DOWNLOAD

COVER. 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS. 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS. 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 41
PRECAUTIONS FOR DEF 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING. 42
PRECAUTIONS FOR ADDING. 42
PRECAUTIONS FOR STORING 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
STORE AdBlue/DEF. 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT. 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT. 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT. 57
PRACTICAL USE OF KOMTRAX. 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS. 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE. 73
HOW TO READ ELECTRICAL WIRE CODE. 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 78
STANDARD TIGHTENING TORQUE TABLE. 81
CONVERSION TABLE. 88
01 SPECIFICATIONS 93
CONTENTS. 94
ABBREVIATION LIST 95
SPECIFICATIONS. 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: D61EX-24 101
SPECIFICATION DRAWING: D61PX-24 103
SPECIFICATIONS. 105
SPECIFICATIONS: D61EX-24. 105
SPECIFICATIONS: D61PX-24. 110
WEIGHT TABLE. 114
WEIGHT TABLE: D61EX-24. 114
WEIGHT TABLE: D61PX-24. 116
TABLE OF FUEL, COOLANT, AND LUBRICANTS. 118
10 STRUCTURE AND FUNCTION 119
CONTENTS. 120
ABBREVIATION LIST 123
UREA SCR SYSTEM 129
LAYOUT DRAWING OF UREA SCR SYSTEM 129
UREA SCR SYSTEM DIAGRAM 132
FUNCTION OF UREA SCR SYSTEM 133
FUNCTION OF AdBlue/DEF SYSTEM 133
INDUCEMENT STRATEGY 135
COMPONENT PARTS OF UREA SCR SYSTEM. 149
AdBlue/DEF MIXING TUBE. 149
SCR ASSEMBLY. 150
AdBlue/DEF TANK 152
AdBlue/DEF PUMP 154
AdBlue/DEF INJECTOR 155
AdBlue/DEF HOSE 156
AdBlue/DEF TANK HEATING VALVE 157
BOOT-UP SYSTEM. 158
LAYOUT DRAWING OF BOOT-UP SYSTEM. 158
SYSTEM OPERATING LAMP SYSTEM. 159
SYSTEM OPERATING LAMP SYSTEM DIAGRAM. 159
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM. 159
BATTERY DISCONNECT SWITCH 161
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 161
FUNCTION OF BATTERY DISCONNECT SWITCH 161
ENGINE SYSTEM 163
LAYOUT DRAWING OF ENGINE SYSTEM 163
ENGINE CONTROL SYSTEM 165
LAYOUT OF ENGINE CONTROL SYSTEM 165
ENGINE CONTROL SYSTEM DIAGRAM 167
FUNCTION OF ENGINE CONTROL SYSTEM 169
AUTOMATIC IDLE STOP SYSTEM. 171
AUTOMATIC IDLE STOP SYSTEM DIAGRAM. 171
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM. 171
COMPONENT PARTS OF ENGINE SYSTEM. 174
DAMPER. 174
VGT 175
EGR SYSTEM. 179
EGR VALVE 181
EGR COOLER. 183
KCCV SYSTEM 185
KCCV VENTILATOR 187
KDPF. 189
COOLING SYSTEM. 193
LAYOUT DRAWING OF COOLING SYSTEM. 193
SPECIFICATIONS OF COOLING SYSTEM. 194
COOLING FAN CONTROL SYSTEM. 195
COOLING FAN CONTROL SYSTEM DIAGRAM. 195
FUNCTION OF COOLING FAN CONTROL SYSTEM. 196
COMPONENT PARTS OF COOLING SYSTEM 198
COOLING FAN MOTOR 198
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 203
HYDRAULIC OIL COOLER BYPASS VALVE 205
HST CHARGE SAFETY VALVE 206
CONTROL SYSTEM. 208
LAYOUT DRAWING OF CONTROL SYSTEM. 208
MACHINE MONITOR SYSTEM. 209
MACHINE MONITOR SYSTEM DIAGRAM. 209
FUNCTION OF MACHINE MONITOR SYSTEM. 209
KOMTRAX SYSTEM. 210
KOMTRAX SYSTEM DIAGRAM. 210
FUNCTION OF KOMTRAX SYSTEM. 210
COMPONENT PARTS OF CONTROL SYSTEM 211
MACHINE MONITOR 211
KOMTRAX TERMINAL. 226
HST CONTROLLER. 228
ENGINE CONTROLLER 232
DECELERATOR AND BRAKE POTENTIOMETER 239
HYDRAULIC SYSTEM. 241
LAYOUT DRAWING OF HYDRAULIC SYSTEM. 241
CLSS. 242
STRUCTURE OF CLSS 242
FUNCTION OF CLSS. 243
COMPONENT PARTS OF HYDRAULIC SYSTEM 245
HYDRAULIC TANK. 245
WORK EQUIPMENT AND COOLING FAN PUMP 247
LS VALVE. 255
PC VALVE. 256
CONTROL VALVE 259
POWER TRAIN SYSTEM. 280
LAYOUT DRAWING OF HST SYSTEM. 280
OPERATION OF HST SYSTEM 281
STEERING AND BRAKE CONTROL SYSTEM 283
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 283
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 283
HST CONTROL SYSTEM. 285
HST CONTROL SYSTEM DIAGRAM. 285
GEAR SHIFT CONTROL FUNCTION 286
ENGINE LOW SPEED MATCHING CONTROL FUNCTION. 290
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION. 290
DECELERATION AND BRAKE CONTROL FUNCTION 292
GEAR SHIFT CONTROL FUNCTION BY LOAD 293
TURN CONTROL FUNCTION 293
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 294
PARKING BRAKE CONTROL SYSTEM. 296
PARKING BRAKE CONTROL SYSTEM DIAGRAM. 296
FUNCTION OF PARKING BRAKE CONTROL SYSTEM. 297
OPERATION OF PARKING BRAKE CONTROL SYSTEM 298
COMPONENT PARTS OF POWER TRAIN SYSTEM 299
HST PUMP. 299
HST CHARGE PUMP 316
HST MOTOR 317
FINAL DRIVE 329
ELECTRIC STEERING CONTROL LEVER 333
WORK EQUIPMENT SYSTEM 336
WORK EQUIPMENT CONTROL. 336
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 336
FUNCTION OF WORK EQUIPMENT CONTROL. 337
LAYOUT DRAWING OF FRONT WORK EQUIPMENT. 339
LAYOUT OF FIXED MULTI-SHANK RIPPER. 340
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM. 341
RIPPER PPC VALVE. 341
5-PORT VALVE OF EPC AND SOLENOID. 345
PILOT CIRCUIT ACCUMULATOR 351
ANGLE CONTROL EPC VALVE 352
QUICK DROP VALVE. 355
PISTON VALVE. 357
ELECTRIC BLADE CONTROL LEVER. 358
UNDERCARRIAGE AND FRAME 360
MAIN FRAME. 360
STRUCTURE OF MAIN FRAME 360
SUSPENSION. 361
STRUCTURE OF SUSPENSION 361
SPECIFICATIONS OF SUSPENSION. 362
FUNCTION OF SUSPENSION. 363
TRACK FRAME AND IDLER CUSHION 364
STRUCTURE OF TRACK FRAME AND IDLER CUSHION. 364
FUNCTION OF TRACK FRAME AND IDLER CUSHION 365
WORK EQUIPMENT. 366
STRUCTURE OF FRONT WORK EQUIPMENT 366
STRUCTURE OF FIXED MULTI-SHANK RIPPER 367
CAB AND ITS ATTACHMENTS 368
ROPS CAB. 368
STRUCTURE OF ROPS CAB 368
FUNCTION OF ROPS CAB. 369
CAB MOUNT 370
STRUCTURE OF CAB MOUNT. 370
FUNCTION OF CAB MOUNT 370
20 STANDARD VALUE TABLE 371
CONTENTS. 372
ABBREVIATION LIST 373
STANDARD VALUE TABLE FOR ENGINE 379
STANDARD VALUE TABLE FOR ENGINE: D61EX-24 379
STANDARD VALUE TABLE FOR ENGINE: D61PX-24 383
STANDARD VALUE TABLE FOR MACHINE. 387
STANDARD VALUE TABLE FOR MACHINE: D61EX-24. 387
STANDARD VALUE TABLE FOR MACHINE: D61PX-24. 403
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 419
30 TESTING AND ADJUSTING. 421
CONTENTS. 422
ABBREVIATION LIST 425
RELATED INFORMATION ON TESTING AND ADJUSTING. 431
TOOLS FOR TESTING AND ADJUSTING 431
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 438
ENGINE AND COOLING SYSTEM 439
TEST ENGINE SPEED 439
METHOD FOR TESTING ENGINE SPEED 439
TEST BOOST PRESSURE 442
METHOD FOR TESTING BOOST PRESSURE 442
TEST EXHAUST GAS COLOR. 444
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 444
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 446
TEST AND ADJUST VALVE CLEARANCE 448
METHOD FOR TESTING VALVE CLEARANCE. 448
METHOD FOR ADJUSTING VALVE CLEARANCE. 449
TEST COMPRESSION PRESSURE 450
METHOD FOR TESTING COMPRESSION PRESSURE 450
TEST BLOWBY PRESSURE. 455
METHOD FOR TESTING BLOWBY PRESSURE. 455
TEST ENGINE OIL PRESSURE. 457
METHOD FOR TESTING ENGINE OIL PRESSURE. 457
TEST EGR VALVE AND VGT OIL PRESSURE 458
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 458
TEST FUEL PRESSURE. 460
METHOD FOR TESTING FUEL PRESSURE. 461
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 466
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 467
BLEEDING AIR FROM FUEL SYSTEM 473
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM. 473
TEST FUEL CIRCUIT FOR LEAKAGE 474
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 474
HANDLE CYLINDER CUT-OUT MODE OPERATION. 476
HANDLE NO-INJECTION CRANKING OPERATION. 477
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 478
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 478
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS. 479
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS. 479
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 480
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 480
TEST ALTERNATOR BELT. 481
METHOD FOR REMOVING ALTERNATOR BELT 481
TEST AUTOMATIC TENSIONER. 483
METHOD FOR TESTING AUTOMATIC TENSIONER. 483
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER. 485
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 485
TEST SCR RELATED FUNCTIONS. 486
TEST AdBlue/DEF PUMP RAISED PRESSURE. 490
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR. 493
TEST AdBlue/DEF LINE HEATER RELAY 1 498
TEST AdBlue/DEF LINE HEATER RELAY 2 501
TEST AdBlue/DEF PUMP HEATER RELAY 504
TEST AdBlue/DEF TANK HEATER VALVE 508
TEST DENITRATION EFFICIENCY OF SCR. 512
CLEAN AdBlue/DEF TANK 515
METHOD FOR CLEANING AdBlue/DEF TANK 515
CLEAN AdBlue/DEF TANK MOUNTING PORTION. 519
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION. 519
POWER TRAIN 520
TEST AND ADJUST HST OIL PRESSURE. 520
METHOD FOR TESTING HST OIL PRESSURE 520
METHOD FOR ADJUSTING HST OIL PRESSURE 523
BLEED AIR FROM HST PUMP 525
METHOD FOR BLEEDING AIR FROM HST PUMP 525
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP. 525
TEST OUTLET PRESSURE OF SOLENOID VALVE. 527
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE. 527
TEST TRAVEL DEVIATION 532
METHOD FOR TESTING TRAVEL DEVIATION 532
TEST BRAKE PERFORMANCE SIMPLY 534
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 534
TEST AND ADJUST DECELERATION/BRAKE PEDAL. 535
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 535
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 537
ADJUST PARKING BRAKE LEVER. 539
METHOD FOR ADJUSTING PARKING BRAKE LEVER. 539
MOVE MACHINE WHEN IT CANNOT TRAVEL. 541
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM. 541
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT. 543
UNDERCARRIAGE AND FRAME 545
CHECK AND ADJUST IDLER CLEARANCE. 545
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE 545
TESTING SPROCKET WEAR 546
METHOD FOR TESTING SPROCKET WEAR. 546
TEST AND ADJUST TRACK TENSION 547
METHOD FOR TESTING TRACK TENSION. 547
METHOD FOR ADJUSTING TRACK TENSION. 547
HYDRAULIC SYSTEM. 549
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. 549
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT. 549
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES. 550
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 550
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 551
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 553
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT. 553
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT. 554
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE. 555
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE. 555
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP. 557
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP. 557
TEST COOLING FAN SPEED. 558
METHOD FOR TESTING COOLING FAN SPEED. 558
TEST COOLING FAN CIRCUIT OIL PRESSURE 559
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 559
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT. 561
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 561
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 562
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER. 563
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER. 564
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER. 564
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 566
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 566
WORK EQUIPMENT. 567
ADJUST WORK EQUIPMENT LOCK LEVER. 567
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER. 567
ELECTRICAL SYSTEM 569
SET AND OPERATE MACHINE MONITOR 569
OPERATOR MODE 573
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 573
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN. 573
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 574
CHECKING FUNCTION OF SERVICE METER. 574
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 574
SERVICE MODE. 577
METHOD FOR OPERATING SERVICE MODE 577
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION. 579
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION. 585
ABNORMALITY RECORD MENU 595
METHOD FOR CONFIRMING MAINTENANCE RECORD. 599
METHOD FOR OPERATING MAINTENANCE MODE SETTING 600
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 604
DEFAULT MENU. 606
DIAGNOSTIC TESTS MENU 613
ADJUSTMENT MENU 622
METHOD FOR PERFORMING NO-INJECTION CRANKING 677
KOMTRAX SETTINGS MENU 680
METHOD FOR DISPLAYING SERVICE MESSAGE 682
METHOD FOR STARTING UP KOMTRAX TERMINAL 684
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED. 689
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 689
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED. 695
ADJUST REARVIEW CAMERA ANGLE. 697
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE. 697
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 698
HANDLE BATTERY DISCONNECT SWITCH. 699
TEST DIODES 700
METHOD FOR TESTING DIODE USING DIGITAL TESTER 700
METHOD FOR TESTING DIODE USING ANALOG TESTER. 700
Pm CLINIC 701
Pm CLINIC SERVICE 701
PM CLINIC CHECK SHEET: D61EX-24 703
PM CLINIC CHECK SHEET: D61PX-24 710
PM CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EX-24 717
PM CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PX-24 720
40 TROUBLESHOOTING. 723
CONTENTS. 724
ABBREVIATION LIST 734
RELATED INFORMATION ON TROUBLESHOOTING. 740
GENERAL TROUBLESHOOTING POINTS. 740
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM. 741
SEQUENCE OF EVENTS IN TROUBLESHOOTING 753
CHECKS BEFORE TROUBLESHOOTING 755
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 757
WALK-AROUND CHECK 757
TESTING IN ACCORDANCE WITH TESTING PROCEDURE. 759
CHECK FUEL LEVEL AND TYPE 759
CHECK IMPURE INGREDIENT IN FUEL 759
CHECK AdBule/DEF LEVEL AND TYPE 760
CHECK FUEL PREFILTER. 760
CHECK MAIN FILTER 762
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 763
CHECK COOLANT LEVEL (RESERVOIR TANK). 764
CHECK CLOGGING OF AIR CLEANER 765
CLEAN OUTER ELEMENT 765
REPLACE ELEMENT 767
CHECK HYDRAULIC OIL LEVEL 768
CHECK HYDRAULIC OIL STRAINER. 769
CHECK HYDRAULIC FILTER. 772
CHECK OIL LEVEL IN FINAL DRIVE CASE 773
BLEED AIR FROM FUEL SYSTEM. 774
BLEED AIR FROM HYDRAULIC SYSTEM 774
METHOD FOR CHECKING ELECTRIC EQUIPMENT. 774
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM. 781
PROCEDURE FOR TROUBLESHOOTING 788
SYMPTOM AND TROUBLESHOOTING NUMBERS 791
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE. 794
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 796
CONNECTORS LIST AND LAYOUT. 799
CONNECTOR CONTACT IDENTIFICATION. 813
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 853
FUSE LOCATION TABLE 859
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 863
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 867
FAILURE CODES TABLE 869
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 887
FAILURE CODE [6091NX] 887
FAILURE CODE [989L00] 889
FAILURE CODE [989M00] 890
FAILURE CODE [989N00] 891
FAILURE CODE [A1U0N3] 892
FAILURE CODE [A1U0N4] 894
FAILURE CODE [A900FR] 896
FAILURE CODE [A900N6] 897
FAILURE CODE [A900NY] 898
FAILURE CODE [AA10NX] 899
FAILURE CODE [AB00KE] 901
FAILURE CODE [AQ10N3] 903
FAILURE CODE [AS00N3] 905
FAILURE CODE [AS00R2] 907
FAILURE CODE [AS00R3] 908
FAILURE CODE [AS00R4] 909
FAILURE CODE [AS00R5] 910
FAILURE CODE [AS00R6] 911
FAILURE CODE [AS00ZK] 912
FAILURE CODE [AS10KM] 913
FAILURE CODE [AS10NR] 914
FAILURE CODE [AS10NT] 915
FAILURE CODE [B@BAZG] 916
FAILURE CODE [B@BCNS] 917
FAILURE CODE [B@CRNS] 918
FAILURE CODE [B@CRZG] 919
FAILURE CODE [CA115]. 920
FAILURE CODE [CA122]. 921
FAILURE CODE [CA123]. 923
FAILURE CODE [CA131]. 925
FAILURE CODE [CA132]. 927
FAILURE CODE [CA144]. 929
FAILURE CODE [CA145]. 931
FAILURE CODE [CA153]. 933
FAILURE CODE [CA154]. 936
FAILURE CODE [CA187]. 938
FAILURE CODE [CA221]. 940
FAILURE CODE [CA222]. 942
FAILURE CODE [CA227]. 944
FAILURE CODE [CA234]. 945
FAILURE CODE [CA238]. 946
FAILURE CODE [CA239]. 948
FAILURE CODE [CA249]. 950
FAILURE CODE [CA256]. 952
FAILURE CODE [CA271]. 954
FAILURE CODE [CA272]. 956
FAILURE CODE [CA322]. 958
FAILURE CODE [CA323]. 960
FAILURE CODE [CA324]. 962
FAILURE CODE [CA325]. 964
FAILURE CODE [CA331]. 966
FAILURE CODE [CA332]. 968
FAILURE CODE [CA343]. 970
FAILURE CODE [CA351]. 971
FAILURE CODE [CA352]. 972
FAILURE CODE [CA356]. 975
FAILURE CODE [CA357]. 977
FAILURE CODE [CA386]. 980
FAILURE CODE [CA428]. 981
FAILURE CODE [CA429]. 983
FAILURE CODE [CA435]. 985
FAILURE CODE [CA441]. 987
FAILURE CODE [CA442]. 989
FAILURE CODE [CA449]. 990
FAILURE CODE [CA451]. 991
FAILURE CODE [CA452]. 993
FAILURE CODE [CA488]. 995
FAILURE CODE [CA515]. 996
FAILURE CODE [CA516]. 998
FAILURE CODE [CA553].1000
FAILURE CODE [CA555].1001
FAILURE CODE [CA556].1002
FAILURE CODE [CA559].1003
FAILURE CODE [CA595].1006
FAILURE CODE [CA687].1007
FAILURE CODE [CA689].1009
FAILURE CODE [CA691].1012
FAILURE CODE [CA692].1014
FAILURE CODE [CA697].1016
FAILURE CODE [CA698].1017
FAILURE CODE [CA731].1018
FAILURE CODE [CA778].1020
FAILURE CODE [CA1117]1025
FAILURE CODE [CA1664]1026
FAILURE CODE [CA1669]1029
FAILURE CODE [CA1673]1030
FAILURE CODE [CA1677]1031
FAILURE CODE [CA1678]1032
FAILURE CODE [CA1682]1033
FAILURE CODE [CA1683]1037
FAILURE CODE [CA1684]1039
FAILURE CODE [CA1686]1041
FAILURE CODE [CA1691]1042
FAILURE CODE [CA1694]1045
FAILURE CODE [CA1695]1048
FAILURE CODE [CA1696]1049
FAILURE CODE [CA1712]1051
FAILURE CODE [CA1713]1054
FAILURE CODE [CA1714]1056
FAILURE CODE [CA1715]1057
FAILURE CODE [CA1776]1058
FAILURE CODE [CA1777]1061
FAILURE CODE [CA1843]1064
FAILURE CODE [CA1844]1066
FAILURE CODE [CA1879]1069
FAILURE CODE [CA1881]1072
FAILURE CODE [CA1883]1074
FAILURE CODE [CA1885]1078
FAILURE CODE [CA1887]1080
FAILURE CODE [CA1921]1082
FAILURE CODE [CA1922]1085
FAILURE CODE [CA1942]1090
FAILURE CODE [CA1993]1091
FAILURE CODE [CA2185]1094
FAILURE CODE [CA2186]1096
FAILURE CODE [CA2249]1098
FAILURE CODE [CA2271]1099
FAILURE CODE [CA2272]1102
FAILURE CODE [CA2288]1105
FAILURE CODE [CA2311]1106
FAILURE CODE [CA2349]1107
FAILURE CODE [CA2353]1110
FAILURE CODE [CA2357]1112
FAILURE CODE [CA2381]1113
FAILURE CODE [CA2382]1116
FAILURE CODE [CA2383]1119
FAILURE CODE [CA2386]1122
FAILURE CODE [CA2387]1124
FAILURE CODE [CA2555]1125
FAILURE CODE [CA2556]1128
FAILURE CODE [CA2637]1131
FAILURE CODE [CA2639]1133
FAILURE CODE [CA2771]1136
FAILURE CODE [CA2777]1142
FAILURE CODE [CA2976]1145
FAILURE CODE [CA3133]1147
FAILURE CODE [CA3134]1149
FAILURE CODE [CA3135]1151
FAILURE CODE [CA3142]1155
FAILURE CODE [CA3143]1156
FAILURE CODE [CA3144]1157
FAILURE CODE [CA3146]1159
FAILURE CODE [CA3147]1160
FAILURE CODE [CA3148]1161
FAILURE CODE [CA3151]1163
FAILURE CODE [CA3165]1169
FAILURE CODE [CA3229]1171
FAILURE CODE [CA3231]1173
FAILURE CODE [CA3232]1175
FAILURE CODE [CA3235]1179
FAILURE CODE [CA3239]1181
FAILURE CODE [CA3241]1184
FAILURE CODE [CA3242]1187
FAILURE CODE [CA3251]1190
FAILURE CODE [CA3253]1192
FAILURE CODE [CA3254]1195
FAILURE CODE [CA3255]1198
FAILURE CODE [CA3256]1201
FAILURE CODE [CA3311]1203
FAILURE CODE [CA3312]1205
FAILURE CODE [CA3313]1208
FAILURE CODE [CA3314]1209
FAILURE CODE [CA3315]1210
FAILURE CODE [CA3316]1213
FAILURE CODE [CA3317]1214
FAILURE CODE [CA3318]1215
FAILURE CODE [CA3319]1218
FAILURE CODE [CA3321]1219
FAILURE CODE [CA3322]1221
FAILURE CODE [CA3419]1224
FAILURE CODE [CA3421]1226
FAILURE CODE [CA3497]1228
FAILURE CODE [CA3498]1229
FAILURE CODE [CA3543]1230
FAILURE CODE [CA3545]1237
FAILURE CODE [CA3547]1239
FAILURE CODE [CA3558]1240
FAILURE CODE [CA3559]1242
FAILURE CODE [CA3562]1244
FAILURE CODE [CA3563]1246
FAILURE CODE [CA3567]1249
FAILURE CODE [CA3568]1252
FAILURE CODE [CA3571]1258
FAILURE CODE [CA3572]1260
FAILURE CODE [CA3574]1262
FAILURE CODE [CA3575]1264
FAILURE CODE [CA3577]1266
FAILURE CODE [CA3578]1268
FAILURE CODE [CA3582]1270
FAILURE CODE [CA3583]1278
FAILURE CODE [CA3596]1280
FAILURE CODE [CA3649]1283
FAILURE CODE [CA3681]1285
FAILURE CODE [CA3682]1290
FAILURE CODE [CA3713]1296
FAILURE CODE [CA3717]1299
FAILURE CODE [CA3718]1300
FAILURE CODE [CA3725]1301
FAILURE CODE [CA3741]1304
FAILURE CODE [CA3748]1305
FAILURE CODE [CA3751]1307
FAILURE CODE [CA3755]1309
FAILURE CODE [CA3866]1311
FAILURE CODE [CA3867]1315
FAILURE CODE [CA3868]1318
FAILURE CODE [CA3899]1322
FAILURE CODE [CA3911]1324
FAILURE CODE [CA3912]1328
FAILURE CODE [CA3932]1330
FAILURE CODE [CA3933]1332
FAILURE CODE [CA3934]1334
FAILURE CODE [CA3935]1337
FAILURE CODE [CA3936]1339
FAILURE CODE [CA4151]1341
FAILURE CODE [CA4152]1345
FAILURE CODE [CA4155]1349
FAILURE CODE [CA4156]1351
FAILURE CODE [CA4157]1354
FAILURE CODE [CA4158]1356
FAILURE CODE [CA4159]1357
FAILURE CODE [CA4161]1358
FAILURE CODE [CA4162]1361
FAILURE CODE [CA4163]1364
FAILURE CODE [CA4164]1366
FAILURE CODE [CA4165]1368
FAILURE CODE [CA4166]1370
FAILURE CODE [CA4168]1372
FAILURE CODE [CA4169]1375
FAILURE CODE [CA4171]1377
FAILURE CODE [CA4249]1380
FAILURE CODE [CA4251]1382
FAILURE CODE [CA4259]1384
FAILURE CODE [CA4261]1387
FAILURE CODE [CA4277]1390
FAILURE CODE [CA4281]1394
FAILURE CODE [CA4459]1397
FAILURE CODE [CA4461]1400
FAILURE CODE [CA4658]1403
FAILURE CODE [CA4731]1407
FAILURE CODE [CA4732]1408
FAILURE CODE [CA4739]1409
FAILURE CODE [CA4768]1410
FAILURE CODE [CA4769]1412
FAILURE CODE [CA4842]1415
FAILURE CODE [CA4952]1419
FAILURE CODE [CA5115]1421
FAILURE CODE [CA5383]1424
FAILURE CODE [D130KA]1426
FAILURE CODE [D130KB]1429
FAILURE CODE [D130KY]1431
FAILURE CODE [D19JKZ]1433
FAILURE CODE [D811MC]1436
FAILURE CODE [D862KA]1437
FAILURE CODE [D8ALKA]1438
FAILURE CODE [D8ALKB]1440
FAILURE CODE [D8AQKR]1442
FAILURE CODE [DAF0MB]1444
FAILURE CODE [DAF0MC]1445
FAILURE CODE [DAF8KB]1446
FAILURE CODE [DAF9KQ]1448
FAILURE CODE [DAFGMC]1449
FAILURE CODE [DAFLKA]1450
FAILURE CODE [DAFLKB]1452
FAILURE CODE [DAFQKR]1454
FAILURE CODE [DAJ000]1455
FAILURE CODE [DAJ0KQ]1456
FAILURE CODE [DAJ0KT]1457
FAILURE CODE [DAJ0MC]1458
FAILURE CODE [DAJ1KK]1459
FAILURE CODE [DAJ2KK]1461
FAILURE CODE [DAJ5KK]1463
FAILURE CODE [DAJ6KK]1466
FAILURE CODE [DAJLKA]1468
FAILURE CODE [DAJLKB]1470
FAILURE CODE [DAJPMA]1472
FAILURE CODE [DAJQKR]1473
FAILURE CODE [DAJRKR]1474
FAILURE CODE [DB2QKR]1475
FAILURE CODE [DB2RKR]1480
FAILURE CODE [DD12KA]1485
FAILURE CODE [DD12KB]1487
FAILURE CODE [DD13KA]1489
FAILURE CODE [DD13KB]1491
FAILURE CODE [DD14KA]1493
FAILURE CODE [DD14KB]1495
FAILURE CODE [DDKAKA]1497
FAILURE CODE [DDKAKB]1499
FAILURE CODE [DDKFL4]1501
FAILURE CODE [DDKGL4]1503
FAILURE CODE [DDKHKA]1505
FAILURE CODE [DDKHKB]1507
FAILURE CODE [DDNLKA]1509
FAILURE CODE [DDNLKB]1511
FAILURE CODE [DDP6KA]1513
FAILURE CODE [DDP6KB]1516
FAILURE CODE [DDP6MA]1518
FAILURE CODE [DDU1FS]1520
FAILURE CODE [DDU1KA]1522
FAILURE CODE [DDU1KY]1525
FAILURE CODE [DFA4KX]1527
FAILURE CODE [DFA4KZ]1528
FAILURE CODE [DFA4L8]1529
FAILURE CODE [DFA5KA]1530
FAILURE CODE [DFA5KB]1533
FAILURE CODE [DFA6KA]1536
FAILURE CODE [DFA6KB]1539
FAILURE CODE [DFA7KX]1542
FAILURE CODE [DFA7KZ]1543
FAILURE CODE [DFA7L8]1544
FAILURE CODE [DFA8KA]1545
FAILURE CODE [DFA8KB]1548
FAILURE CODE [DFA9KA]1551
FAILURE CODE [DFA9KB]1554
FAILURE CODE [DGS1KA]1557
FAILURE CODE [DGS1KX]1560
FAILURE CODE [DH21KA]1561
FAILURE CODE [DH21KB]1563
FAILURE CODE [DHA4KA]1565
FAILURE CODE [DHAAMA]1567
FAILURE CODE [DHACMA]1569
FAILURE CODE [DHH7KA]1571
FAILURE CODE [DHH7KB]1574
FAILURE CODE [DHH8KA]1576
FAILURE CODE [DHH8KB]1579
FAILURE CODE [DHH9KA]1581
FAILURE CODE [DHH9KB]1584
FAILURE CODE [DHHAKA]1586
FAILURE CODE [DHHAKB]1589
FAILURE CODE [DK30KA]1591
FAILURE CODE [DK30KB]1594
FAILURE CODE [DK30KX]1596
FAILURE CODE [DK30KZ]1597
FAILURE CODE [DK30L8]1598
FAILURE CODE [DK31KA]1599
FAILURE CODE [DK31KB]1602
FAILURE CODE [DK40KA]1604
FAILURE CODE [DK40KB]1607
FAILURE CODE [DK55KX]1609
FAILURE CODE [DK55KZ]1610
FAILURE CODE [DK55L8]1611
FAILURE CODE [DK56KA]1612
FAILURE CODE [DK56KB]1615
FAILURE CODE [DK57KA]1617
FAILURE CODE [DK57KB]1620
FAILURE CODE [DLM0KX]1622
FAILURE CODE [DLM1KA]1623
FAILURE CODE [DLM1KB]1625
FAILURE CODE [DLM1MA]1627
FAILURE CODE [DLM2KA]1628
FAILURE CODE [DLM2KB]1630
FAILURE CODE [DLM2MA]1632
FAILURE CODE [DLM3KA]1633
FAILURE CODE [DLM3KB]1635
FAILURE CODE [DLM3MB]1637
FAILURE CODE [DN21FS]1638
FAILURE CODE [DR21KX]1640
FAILURE CODE [DR31KX]1641
FAILURE CODE [DV20KB]1642
FAILURE CODE [DW4BKA]1644
FAILURE CODE [DW4BKB]1646
FAILURE CODE [DW4BKY]1648
FAILURE CODE [DW7BKA]1650
FAILURE CODE [DW7BKB]1652
FAILURE CODE [DW7EKA]1654
FAILURE CODE [DW7EKB]1656
FAILURE CODE [DW7EKY]1658
FAILURE CODE [DWN5KA]1660
FAILURE CODE [DWN5KB]1662
FAILURE CODE [DWN5KY]1664
FAILURE CODE [DXA4KA]1666
FAILURE CODE [DXA4KB]1668
FAILURE CODE [DXA4KY]1670
FAILURE CODE [DXA5KA]1672
FAILURE CODE [DXA5KB]1674
FAILURE CODE [DXA5KY]1676
FAILURE CODE [DXA6KA]1678
FAILURE CODE [DXA6KB]1680
FAILURE CODE [DXA6KY]1682
FAILURE CODE [DXA7KA]1684
FAILURE CODE [DXA7KB]1686
FAILURE CODE [DXA7KY]1688
FAILURE CODE [DXHRKA]1690
FAILURE CODE [DXHRKB]1692
FAILURE CODE [DXHRKY]1694
FAILURE CODE [DXHSKA]1696
FAILURE CODE [DXHSKB]1698
FAILURE CODE [DXHSKY]1700
FAILURE CODE [DXHTKA]1702
FAILURE CODE [DXHTKB]1704
FAILURE CODE [DXHTKY]1706
FAILURE CODE [DXHUKA]1708
FAILURE CODE [DXHUKB]1710
FAILURE CODE [DXHUKY]1712
FAILURE CODE [DXJ4KA]1714
FAILURE CODE [DXJ4KB]1716
FAILURE CODE [DXJCKA]1718
FAILURE CODE [DXJCKB]1720
FAILURE CODE [DXJCKY]1722
FAILURE CODE [DXJDKA]1724
FAILURE CODE [DXJDKB]1726
FAILURE CODE [DXJDKY]1728
FAILURE CODE [DXK1KA]1730
FAILURE CODE [DXK1KB]1732
FAILURE CODE [DXK1KY]1734
FAILURE CODE [DXK2KA]1736
FAILURE CODE [DXK2KB]1738
FAILURE CODE [DXK2KY]1740
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1742
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1742
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK.1749
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1752
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1754
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1756
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP.1760
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.1761
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1762
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1763
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1764
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1765
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1766
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1767
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE1768
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL1769
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE.1772
E-17 OPERATION MODE DOES NOT CHANGE1773
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN1774
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE1775
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1776
E-21 SERVICE MODE CANNOT BE SELECTED.1777
E-22 WORK EQUIPMENT DOES NOT OPERATE.1778
E-23 FOOT HEATER DOES NOT OPERATE1780
E-24 HORN DOES NOT SOUND.1786
E-25 HORN DOES NOT STOP SOUNDING.1788
E-26 BACKUP ALARM DOES NOT SOUND.1789
E-27 BACKUP ALARM DOES NOT STOP SOUNDING.1790
E-28 HEADLAMP DOES NOT LIGHT UP1791
E-29 REAR LAMP DOES NOT LIGHT UP.1795
E-30 ALL WIPERS DO NOT OPERATE.1798
E-31 FRONT WIPER DOES NOT OPERATE1800
E-32 REAR WIPER DOES NOT OPERATE.1802
E-33 LEFT DOOR WIPER DOES NOT OPERATE1804
E-34 RIGHT DOOR WIPER DOES NOT OPERATE.1808
E-35 FRONT WASHER DOES NOT OPERATE.1812
E-36 REAR WASHER DOES NOT OPERATE1814
E-37 LEFT DOOR WASHER DOES NOT OPERATE.1816
E-38 RIGHT DOOR WASHER DOES NOT OPERATE1818
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1820
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1821
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1821
FAILURE MODE AND CAUSE TABLE.1822
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE).1828
H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE)1830
H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)1832
H-4 TRAVEL SPEED OR POWER IS LOW.1834
H-5 SPEED RANGE DOES NOT CHANGE1836
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS.1837
H-7 MACHINE DEVIATES LARGELY.1838
H-8 MACHINE DRIFT ON A SLOPE IS LARGE1841
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS.1843
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR1845
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH1847
H-12 ALL WORK EQUIPMENT DO NOT OPERATE.1849
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW.1851
H-14 BLADE LIFT SPEED OR POWER IS LOW1852
H-15 BLADE TILT SPEED OR POWER IS LOW1854
H-16 BLADE ANGLE SPEED OR POWER IS LOW.1855
H-17 TIME LAG OF BLADE LIFT IS LARGE.1856
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE1857
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE1858
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE.1859
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)1860
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN1862
TROUBLESHOOTING OF ENGINE (S-MODE).1863
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1863
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.1864
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT.1865
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START).1866
S-4 ENGINE STARTABILITY IS POOR1868
S-5 ENGINE DOES NOT PICK UP SMOOTHLY.1870
S-6 ENGINE STOPS DURING OPERATION1872
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE.1874
S-8 ENGINE LACKS POWER.1875
S-9 KDPF GETS CLOGGED IN A SHORT TIME1877
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE.1879
S-11 OIL BECOMES CONTAMINATED QUICKLY1880
S-12 FUEL CONSUMPTION IS EXCESSIVE.1881
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN).1882
S-14 OIL PRESSURE DROPS1883
S-15 FUEL MIXES INTO ENGINE OIL1885
S-16 WATER MIXES INTO ENGINE OIL (MILKY).1886
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)1887
S-18 UNUSUAL NOISE IS HEARD1888
S-19 VIBRATION IS EXCESSIVE1889
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT1890
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY1891
S-22 ACTIVE REGENERATION TAKES TIME1893
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.1894
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE.1895
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)1897
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).1898
50 DISASSEMBLY AND ASSEMBLY1899
CONTENTS.1900
ABBREVIATION LIST1905
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1911
HOW TO READ THIS MANUAL1911
COATING MATERIALS LIST.1913
SPECIAL TOOLS LIST.1917
SKETCHES OF SPECIAL TOOLS1936
ENGINE AND COOLING SYSTEM1949
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY1949
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY.1949
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY.1955
REMOVE AND INSTALL INJECTOR ASSEMBLY.1962
METHOD FOR REMOVING INJECTOR ASSEMBLY1962
METHOD FOR INSTALLING INJECTOR ASSEMBLY1969
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY1979
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY.1979
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY.1991
REMOVE AND INSTALL EGR VALVE ASSEMBLY2009
METHOD FOR REMOVING EGR VALVE ASSEMBLY.2009
METHOD FOR INSTALLING EGR VALVE ASSEMBLY.2010
REMOVE AND INSTALL EGR COOLER ASSEMBLY.2012
METHOD FOR REMOVING EGR COOLER ASSEMBLY2012
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2014
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY.2017
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2017
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2019
REMOVE AND INSTALL ALTERNATOR BELT.2021
METHOD FOR REMOVING ALTERNATOR BELT2021
METHOD FOR INSTALLING ALTERNATOR BELT2022
REMOVE AND INSTALL AUTOMATIC TENSIONER.2024
METHOD FOR REMOVING AUTOMATIC TENSIONER2024
METHOD FOR INSTALLING AUTOMATIC TENSIONER2024
REMOVE AND INSTALL RADIATOR ASSEMBLY.2025
METHOD FOR REMOVING RADIATOR ASSEMBLY2025
METHOD FOR INSTALLING RADIATOR ASSEMBLY2028
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY.2032
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2032
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2035
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2038
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY.2038
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY.2041
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY2045
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY.2045
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY.2048
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY2052
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY.2052
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY.2055
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY.2059
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY2059
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY2068
REMOVE AND INSTALL ENGINE FRONT OIL SEAL.2079
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2079
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2080
REMOVE AND INSTALL ENGINE REAR OIL SEAL2082
METHOD FOR REMOVING ENGINE REAR OIL SEAL.2082
METHOD FOR INSTALLING ENGINE REAR OIL SEAL.2084
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2087
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY.2087
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY.2090
REMOVE AND INSTALL FUEL TANK ASSEMBLY2093
METHOD FOR REMOVING FUEL TANK ASSEMBLY.2093
METHOD FOR INSTALLING FUEL TANK ASSEMBLY.2099
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2105
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY.2105
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY.2111
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2117
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.2117
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.2118
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2121
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR.2121
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR.2122
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2129
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER.2129
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER.2130
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2131
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER.2131
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER.2132
REMOVE AND INSTALL KDPF ASSEMBLY.2135
METHOD FOR REMOVING KDPF ASSEMBLY2136
METHOD FOR INSTALLING KDPF ASSEMBLY2139
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2142
METHOD FOR DISASSEMBLING KDPF ASSEMBLY.2142
METHOD FOR ASSEMBLING KDPF ASSEMBLY2145
REMOVE AND INSTALL SCR ASSEMBLY2152
METHOD FOR REMOVING SCR ASSEMBLY.2152
METHOD FOR INSTALLING SCR ASSEMBLY.2154
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2158
METHOD FOR REMOVING KDPF, SCR ASSEMBLY.2159
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY.2165
REMOVE AND INSTALL KCCV ASSEMBLY.2172
METHOD FOR REMOVING KCCV ASSEMBLY2172
METHOD FOR INSTALLING KCCV ASSEMBLY2174
REMOVE AND INSTALL VGT ASSEMBLY2176
METHOD FOR REMOVING VGT ASSEMBLY.2176
METHOD FOR INSTALLING VGT ASSEMBLY.2178
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2181
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE.2182
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE.2184
REMOVE AND INSTALL AdBlue/DEF INJECTOR.2188
METHOD FOR REMOVING AdBlue/DEF INJECTOR2188
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2191
REMOVE AND INSTALL AdBlue/DEF PUMP.2195
METHOD FOR REMOVING AdBlue/DEF PUMP2195
METHOD FOR INSTALLING AdBlue/DEF PUMP2198
REMOVE AND INSTALL AdBlue/DEF HOSE.2201
METHOD FOR REMOVING AdBlue/DEF HOSE2201
METHOD FOR INSTALLING AdBlue/DEF HOSE2205
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2211
METHOD FOR REMOVING AIR CLEANER ASSEMBLY.2211
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY.2213
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.2216
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2216
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2217
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2219
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY.2219
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY.2223
POWER TRAIN2227
REMOVE AND INSTALL DAMPER ASSEMBLY.2227
METHOD FOR REMOVING DAMPER ASSEMBLY2227
METHOD FOR INSTALLING DAMPER ASSEMBLY2228
REMOVE AND INSTALL HST PUMP ASSEMBLY.2230
METHOD FOR REMOVING HST PUMP ASSEMBLY2230
METHOD FOR INSTALLING HST PUMP ASSEMBLY2232
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY2234
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY.2234
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY.2237
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2240
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2241
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY.2246
UNDERCARRIAGE AND FRAME2255
REMOVE AND INSTALL TRACK FRAME ASSEMBLY2255
METHOD FOR REMOVING TRACK FRAME ASSEMBLY.2255
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY.2259
REMOVE AND INSTALL IDLER ASSEMBLY2264
METHOD FOR REMOVING IDLER ASSEMBLY.2264
METHOD FOR INSTALLING IDLER ASSEMBLY.2266
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2268
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2268
METHOD FOR ASSEMBLING IDLER ASSEMBLY.2270
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY2275
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY.2275
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY.2276
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY2277
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY.2277
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY.2280
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY.2283
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY2283
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY2284
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY.2287
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY.2287
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2289
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY.2293
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY2293
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY2294
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY.2296
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY.2296
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2297
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY2300
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY.2300
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY.2301
SEPARATE AND CONNECT TRACK ASSEMBLY2303
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY.2303
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)2304
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT)2305
METHOD FOR CONNECTING TRACK ASSEMBLY.2306
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY2308
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY.2308
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY.2308
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY2310
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY2310
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY.2315
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY2328
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY2329
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY.2330
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2345
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2346
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD.2347
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2354
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2355
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD.2357
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY2361
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY.2361
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY.2363
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS.2366
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS2366
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS2366
REMOVE AND INSTALL SEGMENT TEETH.2368
METHOD FOR REMOVING SEGMENT TEETH2368
METHOD FOR INSTALLING SEGMENT TEETH2369
HYDRAULIC SYSTEM.2370
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY.2370
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2371
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2375
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2380
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY.2380
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY.2385
WORK EQUIPMENT.2390
REMOVE AND INSTALL BLADE ASSEMBLY2390
METHOD FOR REMOVING BLADE ASSEMBLY.2390
METHOD FOR INSTALLING BLADE ASSEMBLY.2392
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY.2395
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2395
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2397
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.2399
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2400
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY.2401
REMOVE AND INSTALL U-FRAME ASSEMBLY2405
METHOD FOR REMOVING U-FRAME ASSEMBLY.2405
METHOD FOR INSTALLING U-FRAME ASSEMBLY.2407
CAB AND ITS ATTACHMENTS2409
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY.2409
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2409
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2416
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2423
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS).2425
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS).2425
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY.2431
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2431
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2437
REMOVE AND INSTALL RECEIVER DRIER2444
METHOD FOR REMOVING RECEIVER DRIER.2444
METHOD FOR INSTALLING RECEIVER DRIER.2445
REMOVE AND INSTALL OPERATOR’S SEAT.2448
METHOD FOR REMOVING OPERATOR’S SEAT2448
METHOD FOR INSTALLING OPERATOR’S SEAT2449
REMOVE AND INSTALL SEAT BELT.2450
METHOD FOR REMOVING SEAT BELT2450
METHOD FOR INSTALLING SEAT BELT2450
REMOVE AND INSTALL FOOT HEATER ASSEMBLY2452
METHOD FOR REMOVING FOOT HEATER ASSEMBLY.2452
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY.2454
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY2457
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY2457
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY.2458
ELECTRICAL SYSTEM2459
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2459
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY.2459
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY.2460
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY.2464
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY2464
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY2465
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2466
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY.2466
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY.2467
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2469
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR.2469
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR.2471
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2472
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR.2472
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR.2474
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2476
METHOD FOR REMOVING SCR TEMPERATURE SENSOR.2476
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR.2477
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY.2479
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2479
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2480
60 MAINTENANCE STANDARD2481
CONTENTS.2482
ABBREVIATION LIST2484
ENGINE AND COOLING SYSTEM2490
MAINTENANCE STANDARD OF ENGINE MOUNT.2490
MAINTENANCE STANDARD OF DAMPER.2491
MAINTENANCE STANDARD OF COOLING SYSTEM.2492
MAINTENANCE STANDARD OF COOLING FAN MOTOR2494
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP2496
POWER TRAIN2497
MAINTENANCE STANDARD OF HST PUMP.2497
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP2498
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP2499
MAINTENANCE STANDARD OF HST CHARGE PUMP2500
MAINTENANCE STANDARD OF HST MOTOR2502
MAINTENANCE STANDARD OF FINAL DRIVE2503
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE2505
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE.2506
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE2508
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE.2509
UNDERCARRIAGE AND FRAME2511
MAINTENANCE STANDARD OF SUSPENSION.2511
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2513
MAINTENANCE STANDARD OF IDLER2515
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE)2517
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE)2518
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)2519
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)2520
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE2521
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE2522
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE.2523
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE.2525
MAINTENANCE STANDARD OF SINGLE SHOE2527
MAINTENANCE STANDARD OF SWAMP SHOE.2528
HYDRAULIC SYSTEM.2529
MAINTENANCE STANDARD OF HYDRAULIC TANK.2529
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP2530
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP.2531
MAINTENANCE STANDARD OF CONTROL VALVE2533
MAINTENANCE STANDARD OF RIPPER PPC VALVE.2540
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID.2542
MAINTENANCE STANDARD OF EPC VALVE2543
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE2544
MAINTENANCE STANDARD OF QUICK DROP VALVE.2545
WORK EQUIPMENT.2547
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT.2547
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT.2550
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER2551
MAINTENANCE STANDARD OF BLADE TILT CYLINDER2552
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER.2553
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER.2554
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER.2556
CAB AND ITS ATTACHMENTS2557
MAINTENANCE STANDARD OF CAB MOUNT2557
ELECTRICAL SYSTEM2558
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER2558
80 APPENDIX2559
CONTENTS.2560
ABBREVIATION LIST2561
AIR CONDITIONER SYSTEM.2567
PRECAUTIONS FOR REFRIGERANT2567
AIR CONDITIONER COMPONENT2568
SPECIFICATIONS OF AIR CONDITIONER2571
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2572
OUTLINE OF REFRIGERATION CYCLE.2573
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2575
AIR CONDITIONER UNIT.2575
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2575
FUNCTION OF AIR CONDITIONER UNIT.2576
COMPONENT PARTS OF AIR CONDITIONER UNIT2577
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT.2577
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2577
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT.2577
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT.2578
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2578
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2578
FUNCTION OF DUAL PRESSURE SWITCH.2579
FUNCTION OF PRESSURE SWITCH2579
COMPRESSOR.2580
STRUCTURE OF COMPRESSOR2580
SPECIFICATIONS OF COMPRESSOR.2580
FUNCTION OF COMPRESSOR.2580
CONDENSER2581
STRUCTURE OF CONDENSER.2581
SPECIFICATIONS OF CONDENSER2581
FUNCTION OF CONDENSER2582
RECEIVER DRIER.2583
STRUCTURE OF RECEIVER DRIER2583
SPECIFICATIONS OF RECEIVER DRIER.2583
FUNCTION OF RECEIVER DRIER.2583
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2585
CIRCUIT DIAGRAM OF AIR CONDITIONER.2588
AIR CONDITIONER SYSTEM DIAGRAM.2589
CONTROL FUNCTION OF AIR CONDITIONER2590
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2591
TEST RELAYS2595
METHOD FOR TESTING RELAYS2595
AIR CONDITIONER TROUBLESHOOTING CHART 12597
AIR CONDITIONER TROUBLESHOOTING CHART 22598
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.2601
A-1 TROUBLESHOOTING FOR CONDENSER FAN2603
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2606
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL).2610
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION.2613
TROUBLESHOOTING USING GAUGE PRESSURE.2617
CONNECTION OF SERVICE TOOL.2619
METHOD FOR CONNECTING SERVICE TOOL.2619
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2620
HANDLE COMPRESSOR OIL2622
90 CIRCUIT DIAGRAMS2625
CONTENTS.2626
ABBREVIATION LIST2627
HYDRAULIC CIRCUIT DIAGRAM2633
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2633
HYDRAULIC CIRCUIT DIAGRAM2637
ELECTRICAL CIRCUIT DIAGRAM.2639
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM.2639
ELECTRICAL CIRCUIT DIAGRAM (1/14)2643
ELECTRICAL CIRCUIT DIAGRAM (2/14)2645
ELECTRICAL CIRCUIT DIAGRAM (3/14)2647
ELECTRICAL CIRCUIT DIAGRAM (4/14)2649
ELECTRICAL CIRCUIT DIAGRAM (5/14)2651
ELECTRICAL CIRCUIT DIAGRAM (6/14)2653
ELECTRICAL CIRCUIT DIAGRAM (7/14)2655
ELECTRICAL CIRCUIT DIAGRAM (8/14)2657
ELECTRICAL CIRCUIT DIAGRAM (9/14)2659
ELECTRICAL CIRCUIT DIAGRAM (10/14).2661
ELECTRICAL CIRCUIT DIAGRAM (11/14).2663
ELECTRICAL CIRCUIT DIAGRAM (12/14).2665
ELECTRICAL CIRCUIT DIAGRAM (13/14).2667
ELECTRICAL CIRCUIT DIAGRAM (14/14).2669
INDEX.2671

DESCRIPTION:

Komatsu Engine D61EX-24 D61PX-24 Series Shop Manual SEN06577-06 PDF – DOWNLOAD

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.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively

G. B 12/12/24