Komatsu D61EX-24 D61PX-24 Bulldozer Service Manual KEBM657710 PDF

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Komatsu BULLDOZER D61EX-24,D61PX-24 Shop Manual KEBM657710 –  PDF DOWNLOAD

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Komatsu BULLDOZER D61EX-24,D61PX-24 Shop Manual KEBM657710 –  PDF DOWNLOAD

Language : English
Pages : 2874
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu BULLDOZER D61EX-24,D61PX-24 Shop Manual KEBM657710 –  PDF DOWNLOAD

• D61EX-B60001 and up
• D61PX-B60001 and up

COVER . 0
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS . 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
PRECAUTIONS FOR DEF 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING . 43
PRECAUTIONS FOR ADDING . 43
PRECAUTIONS FOR STORING 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 43
THE OTHER PRECAUTIONS 43
STORE AdBlue/DEF . 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 58
PRACTICAL USE OF KOMTRAX . 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 74
HOW TO READ ELECTRICAL WIRE CODE . 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE . 82
CONVERSION TABLE . 89
01 SPECIFICATIONS 95
CONTENTS . 96
ABBREVIATION LIST 97
SPECIFICATIONS . 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: D61EX-24 103
SPECIFICATION DRAWING: D61PX-24 105
SPECIFICATIONS . 107
SPECIFICATIONS: D61EX-24 . 107
SPECIFICATIONS: D61PX-24 . 112
WEIGHT TABLE . 116
WEIGHT TABLE: D61EX-24 . 116
WEIGHT TABLE: D61PX-24 . 118
TABLE OF FUEL, COOLANT, AND LUBRICANTS . 120
10 STRUCTURE AND FUNCTION 121
CONTENTS . 122
ABBREVIATION LIST 125
UREA SCR SYSTEM 131
LAYOUT DRAWING OF UREA SCR SYSTEM 131
UREA SCR SYSTEM DIAGRAM 134
FUNCTION OF UREA SCR SYSTEM 135
FUNCTION OF AdBlue/DEF SYSTEM 135
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM . 151
AdBlue/DEF MIXING TUBE . 151
SCR ASSEMBLY . 152
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM . 160
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 160
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 161
SYSTEM OPERATING LAMP SYSTEM . 162
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 162
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 162
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 162
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 163
BATTERY DISCONNECT SWITCH 165
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 165
FUNCTION OF BATTERY DISCONNECT SWITCH 165
ENGINE SYSTEM 167
LAYOUT DRAWING OF ENGINE SYSTEM 167
ENGINE CONTROL SYSTEM 169
LAYOUT OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 169
LAYOUT OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 171
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 173
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 175
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 177
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 179
AUTOMATIC IDLE STOP SYSTEM . 181
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 181
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 182
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 182
COMPONENT PARTS OF ENGINE SYSTEM . 185
DAMPER . 185
VGT 186
EGR SYSTEM . 190
EGR VALVE 192
EGR COOLER . 194
KCCV SYSTEM 196
KCCV VENTILATOR 198
KDPF . 200
COOLING SYSTEM . 204
LAYOUT DRAWING OF COOLING SYSTEM . 204
SPECIFICATIONS OF COOLING SYSTEM . 205
COOLING FAN CONTROL SYSTEM . 206
COOLING FAN CONTROL SYSTEM DIAGRAM . 206
FUNCTION OF COOLING FAN CONTROL SYSTEM . 207
COMPONENT PARTS OF COOLING SYSTEM 209
COOLING FAN MOTOR 209
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 214
HYDRAULIC OIL COOLER BYPASS VALVE 216
HST CHARGE SAFETY VALVE 217
CONTROL SYSTEM . 219
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 219
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 220
MACHINE MONITOR SYSTEM . 221
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 221
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 222
FUNCTION OF MACHINE MONITOR SYSTEM . 222
KOMTRAX SYSTEM . 223
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 223
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 223
FUNCTION OF KOMTRAX SYSTEM . 224
COMPONENT PARTS OF CONTROL SYSTEM 225
MACHINE MONITOR 225
KOMTRAX TERMINAL . 240
GATEWAY FUNCTION CONTROLLER 242
COMMUNICATION TERMINAL . 245
HST CONTROLLER . 247
ENGINE CONTROLLER 251
DECELERATOR AND BRAKE POTENTIOMETER 258
HYDRAULIC SYSTEM . 260
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 260
CLSS . 261
STRUCTURE OF CLSS 261
FUNCTION OF CLSS . 262
COMPONENT PARTS OF HYDRAULIC SYSTEM 264
HYDRAULIC TANK . 264
WORK EQUIPMENT AND COOLING FAN PUMP 266
LS VALVE . 274
PC VALVE . 275
CONTROL VALVE 278
POWER TRAIN SYSTEM . 299
LAYOUT DRAWING OF HST SYSTEM . 299
OPERATION OF HST SYSTEM 300
STEERING AND BRAKE CONTROL SYSTEM 302
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 302
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 302
HST CONTROL SYSTEM . 304
HST CONTROL SYSTEM DIAGRAM . 304
GEAR SHIFT CONTROL FUNCTION 305
ENGINE LOW SPEED MATCHING CONTROL FUNCTION . 309
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION . 309
DECELERATION AND BRAKE CONTROL FUNCTION 311
GEAR SHIFT CONTROL FUNCTION BY LOAD 312
TURN CONTROL FUNCTION 312
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 313
PARKING BRAKE CONTROL SYSTEM . 315
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 315
FUNCTION OF PARKING BRAKE CONTROL SYSTEM . 316
OPERATION OF PARKING BRAKE CONTROL SYSTEM 317
COMPONENT PARTS OF POWER TRAIN SYSTEM 318
HST PUMP . 318
HST CHARGE PUMP 335
HST MOTOR 336
FINAL DRIVE 348
ELECTRIC STEERING CONTROL LEVER 352
WORK EQUIPMENT SYSTEM 355
WORK EQUIPMENT CONTROL . 355
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 355
FUNCTION OF WORK EQUIPMENT CONTROL . 356
LAYOUT DRAWING OF FRONT WORK EQUIPMENT . 358
LAYOUT OF FIXED MULTI-SHANK RIPPER . 359
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 360
RIPPER PPC VALVE . 360
5-PORT VALVE OF EPC AND SOLENOID . 364
PILOT CIRCUIT ACCUMULATOR 370
ANGLE CONTROL EPC VALVE 371
QUICK DROP VALVE . 374
PISTON VALVE . 376
ELECTRIC BLADE CONTROL LEVER . 377
UNDERCARRIAGE AND FRAME 379
MAIN FRAME . 379
STRUCTURE OF MAIN FRAME 379
SUSPENSION . 380
STRUCTURE OF SUSPENSION 380
SPECIFICATIONS OF SUSPENSION . 381
FUNCTION OF SUSPENSION . 382
TRACK FRAME AND IDLER CUSHION 383
STRUCTURE OF TRACK FRAME AND IDLER CUSHION . 383
FUNCTION OF TRACK FRAME AND IDLER CUSHION 384
WORK EQUIPMENT . 386
STRUCTURE OF FRONT WORK EQUIPMENT 386
STRUCTURE OF FIXED MULTI-SHANK RIPPER 387
CAB AND ITS ATTACHMENTS 388
ROPS CAB . 388
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) 388
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 389
FUNCTION OF ROPS CAB . 390
CAB MOUNT 391
STRUCTURE OF CAB MOUNT . 391
FUNCTION OF CAB MOUNT 391
20 STANDARD VALUE TABLE 393
CONTENTS . 394
ABBREVIATION LIST 395
STANDARD VALUE TABLE FOR ENGINE 401
STANDARD VALUE TABLE FOR ENGINE: D61EX-24 401
STANDARD VALUE TABLE FOR ENGINE: D61PX-24 405
STANDARD VALUE TABLE FOR MACHINE . 409
STANDARD VALUE TABLE FOR MACHINE: D61EX-24 . 409
STANDARD VALUE TABLE FOR MACHINE: D61PX-24 . 425
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 441
30 TESTING AND ADJUSTING . 443
CONTENTS . 444
ABBREVIATION LIST 448
RELATED INFORMATION ON TESTING AND ADJUSTING . 454
TOOLS FOR TESTING AND ADJUSTING 454
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 462
ENGINE AND COOLING SYSTEM 465
TEST ENGINE SPEED 465
METHOD FOR TESTING ENGINE SPEED 465
TEST BOOST PRESSURE 468
METHOD FOR TESTING BOOST PRESSURE 468
TEST EXHAUST GAS COLOR . 470
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 470
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 472
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 474
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 474
TEST AND ADJUST VALVE CLEARANCE 476
METHOD FOR TESTING VALVE CLEARANCE . 476
METHOD FOR ADJUSTING VALVE CLEARANCE . 477
TEST COMPRESSION PRESSURE 478
METHOD FOR TESTING COMPRESSION PRESSURE 478
TEST BLOWBY PRESSURE . 483
METHOD FOR TESTING BLOWBY PRESSURE . 483
TEST ENGINE OIL PRESSURE . 486
METHOD FOR TESTING ENGINE OIL PRESSURE . 486
TEST EGR VALVE AND VGT OIL PRESSURE 487
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 487
TEST FUEL PRESSURE . 489
METHOD FOR TESTING FUEL PRESSURE . 490
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 495
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 496
BLEEDING AIR FROM FUEL SYSTEM 502
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 502
TEST FUEL CIRCUIT FOR LEAKAGE 503
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 503
HANDLE CYLINDER CUT-OUT MODE OPERATION . 505
HANDLE NO-INJECTION CRANKING OPERATION . 506
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 507
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 507
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 508
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 508
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 509
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 509
TEST ALTERNATOR BELT . 510
METHOD FOR REMOVING ALTERNATOR BELT 510
TEST AUTOMATIC TENSIONER . 512
METHOD FOR TESTING AUTOMATIC TENSIONER . 512
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 514
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 514
TEST SCR RELATED FUNCTIONS . 515
TEST AdBlue/DEF PUMP RAISED PRESSURE . 519
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 522
TEST AdBlue/DEF LINE HEATER RELAY 1 527
TEST AdBlue/DEF LINE HEATER RELAY 2 530
TEST AdBlue/DEF PUMP HEATER RELAY 533
TEST AdBlue/DEF TANK HEATER VALVE 537
TEST DENITRATION EFFICIENCY OF SCR . 541
CLEAN AdBlue/DEF TANK 544
METHOD FOR CLEANING AdBlue/DEF TANK 544
CLEAN AdBlue/DEF TANK MOUNTING PORTION . 548
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION . 548
CLEAN AdBlue/DEF PUMP 549
CLEAN AdBlue/DEF PUMP 549
POWER TRAIN 555
TEST AND ADJUST HST OIL PRESSURE . 555
METHOD FOR TESTING HST OIL PRESSURE 555
METHOD FOR ADJUSTING HST OIL PRESSURE 558
BLEED AIR FROM HST PUMP 560
METHOD FOR BLEEDING AIR FROM HST PUMP 560
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP . 560
TEST OUTLET PRESSURE OF SOLENOID VALVE . 562
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE . 562
TEST TRAVEL DEVIATION 567
METHOD FOR TESTING TRAVEL DEVIATION 567
TEST BRAKE PERFORMANCE SIMPLY 569
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 569
TEST AND ADJUST DECELERATION/BRAKE PEDAL . 570
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 570
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 572
ADJUST PARKING BRAKE LEVER . 574
METHOD FOR ADJUSTING PARKING BRAKE LEVER . 574
MOVE MACHINE WHEN IT CANNOT TRAVEL . 576
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM . 576
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT . 578
UNDERCARRIAGE AND FRAME 580
CHECK AND ADJUST IDLER CLEARANCE . 580
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE 580
TESTING SPROCKET WEAR 581
METHOD FOR TESTING SPROCKET WEAR . 581
TEST AND ADJUST TRACK TENSION 582
METHOD FOR TESTING TRACK TENSION . 582
METHOD FOR ADJUSTING TRACK TENSION . 582
HYDRAULIC SYSTEM . 584
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM . 584
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT . 584
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES . 585
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 585
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 586
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 588
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT . 588
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT . 589
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE . 590
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE . 590
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP . 592
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP . 592
TEST COOLING FAN SPEED . 593
METHOD FOR TESTING COOLING FAN SPEED . 593
TEST COOLING FAN CIRCUIT OIL PRESSURE 594
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 594
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT . 596
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 596
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 596
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER . 597
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 598
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 598
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 601
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 601
WORK EQUIPMENT . 602
ADJUST WORK EQUIPMENT LOCK LEVER . 602
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER . 602
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER . 604
TEST PLAY OF BLADE ELECTRIC LEVER 606
ADJUST PLAY OF BLADE ELECTRIC LEVER 606
REPLACE UNIVERSAL JOINT 607
ELECTRICAL SYSTEM 614
SET AND OPERATE MACHINE MONITOR 614
OPERATOR MODE 618
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 618
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 618
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 619
CHECKING FUNCTION OF SERVICE METER . 619
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 619
SERVICE MODE . 622
METHOD FOR OPERATING SERVICE MODE 622
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 624
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 630
ABNORMALITY RECORD MENU 640
METHOD FOR CONFIRMING MAINTENANCE RECORD . 644
METHOD FOR OPERATING MAINTENANCE MODE SETTING 645
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 649
DEFAULT MENU . 651
DIAGNOSTIC TESTS MENU 658
ADJUSTMENT MENU 667
METHOD FOR PERFORMING NO-INJECTION CRANKING 722
KOMTRAX SETTINGS MENU 725
METHOD FOR DISPLAYING SERVICE MESSAGE 729
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 731
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) . 736
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 738
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 744
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED . 746
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 746
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED . 752
ADJUST REARVIEW CAMERA ANGLE . 754
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE . 754
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 755
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) . 756
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 757
TEST DIODES 758
METHOD FOR TESTING DIODE USING DIGITAL TESTER 758
METHOD FOR TESTING DIODE USING ANALOG TESTER . 758
Pm CLINIC 759
Pm CLINIC SERVICE 759
PM CLINIC CHECK SHEET: D61EX-24 761
PM CLINIC CHECK SHEET: D61PX-24 768
PM CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EX-24 775
PM CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PX-24 778
40 TROUBLESHOOTING . 781
CONTENTS . 782
ABBREVIATION LIST 792
RELATED INFORMATION ON TROUBLESHOOTING . 798
GENERAL TROUBLESHOOTING POINTS . 798
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 799
SEQUENCE OF EVENTS IN TROUBLESHOOTING 814
CHECKS BEFORE TROUBLESHOOTING 816
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 818
WALK-AROUND CHECK 818
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 820
CHECK FUEL LEVEL AND TYPE 820
CHECK IMPURE INGREDIENT IN FUEL 820
CHECK AdBule/DEF LEVEL AND TYPE 821
CHECK FUEL PREFILTER . 821
CHECK MAIN FILTER 823
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 824
CHECK COOLANT LEVEL (RESERVOIR TANK) . 825
CHECK CLOGGING OF AIR CLEANER 826
CLEAN OUTER ELEMENT 826
REPLACE ELEMENT 829
CHECK HYDRAULIC OIL LEVEL 829
CHECK HYDRAULIC OIL STRAINER . 830
CHECK HYDRAULIC FILTER . 833
CHECK OIL LEVEL IN FINAL DRIVE CASE 834
BLEED AIR FROM FUEL SYSTEM . 835
BLEED AIR FROM HYDRAULIC SYSTEM 835
METHOD FOR CHECKING ELECTRIC EQUIPMENT . 835
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM 842
PROCEDURE FOR TROUBLESHOOTING 849
SYMPTOM AND TROUBLESHOOTING NUMBERS 852
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 855
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 857
CONNECTORS LIST AND LAYOUT (MACHINE WITH KOMTRAX TERMINAL) . 860
CONNECTORS LIST AND LAYOUT (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 874
CONNECTOR CONTACT IDENTIFICATION . 888
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 928
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) 934
FUSE LOCATION TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 938
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 942
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 946
FAILURE CODES TABLE (MACHINE WITH KOMTRAX TERMINAL) 948
FAILURE CODES TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 966
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 985
FAILURE CODE [6091NX] 985
FAILURE CODE [989L00] 987
FAILURE CODE [989M00] 988
FAILURE CODE [989N00] 989
FAILURE CODE [A1U0N3] 990
FAILURE CODE [A1U0N4] 992
FAILURE CODE [A900FR] 994
FAILURE CODE [A900N6] 995
FAILURE CODE [A900NY] 996
FAILURE CODE [AA10NX] 997
FAILURE CODE [AB00KE] 999
FAILURE CODE [AQ10N3] 1001
FAILURE CODE [AS00N3] 1003
FAILURE CODE [AS00R2] 1005
FAILURE CODE [AS00R3] 1006
FAILURE CODE [AS00R4] 1007
FAILURE CODE [AS00R5] 1008
FAILURE CODE [AS00R6] 1009
FAILURE CODE [AS00ZK] 1010
FAILURE CODE [AS10KM] 1011
FAILURE CODE [AS10NR] 1012
FAILURE CODE [AS10NT] 1013
FAILURE CODE [B@BAZG] 1014
FAILURE CODE [B@BCNS] 1015
FAILURE CODE [B@CRNS] 1016
FAILURE CODE [B@CRZG] 1017
FAILURE CODE [CA115] .1018
FAILURE CODE [CA122] .1019
FAILURE CODE [CA123] .1021
FAILURE CODE [CA131] .1023
FAILURE CODE [CA132] .1025
FAILURE CODE [CA144] .1027
FAILURE CODE [CA145] .1029
FAILURE CODE [CA153] .1031
FAILURE CODE [CA154] .1034
FAILURE CODE [CA187] .1036
FAILURE CODE [CA221] .1038
FAILURE CODE [CA222] .1040
FAILURE CODE [CA227] .1042
FAILURE CODE [CA234] .1043
FAILURE CODE [CA238] .1044
FAILURE CODE [CA239] .1046
FAILURE CODE [CA249] .1048
FAILURE CODE [CA256] .1050
FAILURE CODE [CA271] .1052
FAILURE CODE [CA272] .1054
FAILURE CODE [CA322] .1056
FAILURE CODE [CA323] .1058
FAILURE CODE [CA324] .1060
FAILURE CODE [CA325] .1062
FAILURE CODE [CA331] .1064
FAILURE CODE [CA332] .1066
FAILURE CODE [CA343] .1068
FAILURE CODE [CA351] .1069
FAILURE CODE [CA352] .1070
FAILURE CODE [CA356] .1073
FAILURE CODE [CA357] .1075
FAILURE CODE [CA386] .1078
FAILURE CODE [CA428] .1079
FAILURE CODE [CA429] .1081
FAILURE CODE [CA435] .1083
FAILURE CODE [CA441] .1085
FAILURE CODE [CA442] .1087
FAILURE CODE [CA449] .1088
FAILURE CODE [CA451] .1089
FAILURE CODE [CA452] .1091
FAILURE CODE [CA488] .1093
FAILURE CODE [CA515] .1094
FAILURE CODE [CA516] .1096
FAILURE CODE [CA553] .1098
FAILURE CODE [CA555] .1099
FAILURE CODE [CA556] .1100
FAILURE CODE [CA559] .1101
FAILURE CODE [CA595] .1104
FAILURE CODE [CA687] .1105
FAILURE CODE [CA689] .1107
FAILURE CODE [CA691] .1110
FAILURE CODE [CA692] .1112
FAILURE CODE [CA697] .1114
FAILURE CODE [CA698] .1115
FAILURE CODE [CA731] .1116
FAILURE CODE [CA778] .1118
FAILURE CODE [CA1117] 1123
FAILURE CODE [CA1664] 1124
FAILURE CODE [CA1669] 1127
FAILURE CODE [CA1673] 1128
FAILURE CODE [CA1677] 1129
FAILURE CODE [CA1678] 1130
FAILURE CODE [CA1682] 1131
FAILURE CODE [CA1683] 1135
FAILURE CODE [CA1684] 1137
FAILURE CODE [CA1686] 1139
FAILURE CODE [CA1691] 1140
FAILURE CODE [CA1694] 1143
FAILURE CODE [CA1695] 1146
FAILURE CODE [CA1696] 1147
FAILURE CODE [CA1712] 1149
FAILURE CODE [CA1713] 1152
FAILURE CODE [CA1714] 1154
FAILURE CODE [CA1715] 1155
FAILURE CODE [CA1776] 1156
FAILURE CODE [CA1777] 1159
FAILURE CODE [CA1843] 1162
FAILURE CODE [CA1844] 1164
FAILURE CODE [CA1879] 1167
FAILURE CODE [CA1881] 1170
FAILURE CODE [CA1883] 1172
FAILURE CODE [CA1885] 1176
FAILURE CODE [CA1887] 1178
FAILURE CODE [CA1921] 1180
FAILURE CODE [CA1922] 1183
FAILURE CODE [CA1942] 1188
FAILURE CODE [CA1993] 1189
FAILURE CODE [CA2185] 1192
FAILURE CODE [CA2186] 1194
FAILURE CODE [CA2249] 1196
FAILURE CODE [CA2271] 1197
FAILURE CODE [CA2272] 1200
FAILURE CODE [CA2288] 1203
FAILURE CODE [CA2311] 1204
FAILURE CODE [CA2349] 1205
FAILURE CODE [CA2353] 1208
FAILURE CODE [CA2357] 1210
FAILURE CODE [CA2381] 1211
FAILURE CODE [CA2382] 1214
FAILURE CODE [CA2383] 1217
FAILURE CODE [CA2386] 1220
FAILURE CODE [CA2387] 1222
TROUBLESHOOTING FLOWCHART 1226
FAILURE CODE [CA2555] 1227
FAILURE CODE [CA2556] 1230
FAILURE CODE [CA2637] 1233
FAILURE CODE [CA2639] 1235
FAILURE CODE [CA2771] 1238
FAILURE CODE [CA2777] 1244
FAILURE CODE [CA2976] 1247
FAILURE CODE [CA3133] 1249
FAILURE CODE [CA3134] 1251
FAILURE CODE [CA3135] 1253
FAILURE CODE [CA3142] 1257
FAILURE CODE [CA3143] 1258
FAILURE CODE [CA3144] 1259
FAILURE CODE [CA3146] 1261
FAILURE CODE [CA3147] 1262
FAILURE CODE [CA3148] 1263
FAILURE CODE [CA3151] 1265
FAILURE CODE [CA3165] 1271
FAILURE CODE [CA3229] 1274
FAILURE CODE [CA3231] 1276
FAILURE CODE [CA3232] 1278
FAILURE CODE [CA3235] 1282
FAILURE CODE [CA3239] 1284
FAILURE CODE [CA3241] 1287
FAILURE CODE [CA3242] 1290
FAILURE CODE [CA3251] 1293
FAILURE CODE [CA3253] 1295
FAILURE CODE [CA3254] 1298
FAILURE CODE [CA3255] 1301
FAILURE CODE [CA3256] 1304
FAILURE CODE [CA3311] 1306
FAILURE CODE [CA3312] 1308
FAILURE CODE [CA3313] 1311
FAILURE CODE [CA3314] 1312
FAILURE CODE [CA3315] 1313
FAILURE CODE [CA3316] 1316
FAILURE CODE [CA3317] 1317
FAILURE CODE [CA3318] 1318
FAILURE CODE [CA3319] 1321
FAILURE CODE [CA3321] 1322
FAILURE CODE [CA3322] 1324
FAILURE CODE [CA3419] 1327
FAILURE CODE [CA3421] 1329
FAILURE CODE [CA3497] 1331
FAILURE CODE [CA3498] 1332
FAILURE CODE [CA3543] 1333
FAILURE CODE [CA3545] 1340
FAILURE CODE [CA3547] 1342
FAILURE CODE [CA3558] 1343
FAILURE CODE [CA3559] 1345
FAILURE CODE [CA3562] 1347
FAILURE CODE [CA3563] 1349
FAILURE CODE [CA3567] 1352
FAILURE CODE [CA3568] 1356
FAILURE CODE [CA3571] 1362
FAILURE CODE [CA3572] 1364
FAILURE CODE [CA3574] 1366
FAILURE CODE [CA3575] 1369
FAILURE CODE [CA3577] 1371
FAILURE CODE [CA3578] 1373
FAILURE CODE [CA3582] 1375
FAILURE CODE [CA3583] 1383
FAILURE CODE [CA3596] 1385
FAILURE CODE [CA3649] 1388
FAILURE CODE [CA3681] 1390
FAILURE CODE [CA3682] 1395
FAILURE CODE [CA3713] 1401
FAILURE CODE [CA3717] 1404
FAILURE CODE [CA3718] 1405
FAILURE CODE [CA3725] 1406
FAILURE CODE [CA3741] 1409
FAILURE CODE [CA3748] 1410
FAILURE CODE [CA3751] 1412
FAILURE CODE [CA3755] 1414
FAILURE CODE [CA3866] 1416
FAILURE CODE [CA3867] 1420
FAILURE CODE [CA3868] 1423
FAILURE CODE [CA3899] 1427
FAILURE CODE [CA3911] 1429
FAILURE CODE [CA3912] 1433
FAILURE CODE [CA3932] 1435
FAILURE CODE [CA3933] 1437
FAILURE CODE [CA3934] 1439
FAILURE CODE [CA3935] 1442
FAILURE CODE [CA3936] 1444
FAILURE CODE [CA4151] 1446
FAILURE CODE [CA4152] 1450
FAILURE CODE [CA4155] 1454
FAILURE CODE [CA4156] 1457
FAILURE CODE [CA4157] 1460
FAILURE CODE [CA4158] 1462
FAILURE CODE [CA4159] 1463
FAILURE CODE [CA4161] 1464
FAILURE CODE [CA4162] 1467
FAILURE CODE [CA4163] 1470
FAILURE CODE [CA4164] 1472
FAILURE CODE [CA4165] 1474
FAILURE CODE [CA4166] 1476
FAILURE CODE [CA4168] 1478
FAILURE CODE [CA4169] 1481
FAILURE CODE [CA4171] 1483
FAILURE CODE [CA4249] 1486
FAILURE CODE [CA4251] 1488
FAILURE CODE [CA4259] 1490
FAILURE CODE [CA4261] 1493
FAILURE CODE [CA4277] 1496
FAILURE CODE [CA4281] 1500
FAILURE CODE [CA4459] 1503
FAILURE CODE [CA4461] 1506
FAILURE CODE [CA4658] 1509
FAILURE CODE [CA4731] 1513
FAILURE CODE [CA4732] 1514
FAILURE CODE [CA4739] 1515
FAILURE CODE [CA4768] 1516
FAILURE CODE [CA4769] 1518
FAILURE CODE [CA4842] 1521
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) 1525
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1527
FAILURE CODE [CA5115] 1529
FAILURE CODE [CA5383] 1532
FAILURE CODE [D130KA] 1534
FAILURE CODE [D130KB] 1537
FAILURE CODE [D130KY] 1539
FAILURE CODE [D19JKZ] 1541
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) 1544
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1545
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) 1546
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1547
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) 1548
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1550
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) 1552
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1554
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) 1556
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1558
FAILURE CODE [D8G1KT] 1560
FAILURE CODE [D8G6KT] 1561
FAILURE CODE [DAF0MB] 1562
FAILURE CODE [DAF0MC] 1563
FAILURE CODE [DAF8KB] 1564
FAILURE CODE [DAF9KQ] 1566
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL) 1567
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1568
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) 1569
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1571
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) 1573
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1575
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) 1577
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1578
FAILURE CODE [DAJ000] 1579
FAILURE CODE [DAJ0KQ] 1580
FAILURE CODE [DAJ0KT] 1581
FAILURE CODE [DAJ0MC] 1582
FAILURE CODE [DAJ1KK] 1583
FAILURE CODE [DAJ2KK] 1585
FAILURE CODE [DAJ5KK] 1587
FAILURE CODE [DAJ6KK] 1590
FAILURE CODE [DAJLKA] (MACHINE WITH KOMTRAX TERMINAL) 1592
FAILURE CODE [DAJLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1594
FAILURE CODE [DAJLKB] (MACHINE WITH KOMTRAX TERMINAL) 1596
FAILURE CODE [DAJLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1598
FAILURE CODE [DAJPMA] 1600
FAILURE CODE [DAJQKR] (MACHINE WITH KOMTRAX TERMINAL) 1601
FAILURE CODE [DAJQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1602
FAILURE CODE [DAJRKR] 1603
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) 1604
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1609
FAILURE CODE [DB2RKR] (MACHINE WITH KOMTRAX TERMINAL) 1614
FAILURE CODE [DB2RKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1619
FAILURE CODE [DD12KA] 1624
FAILURE CODE [DD12KB] 1626
FAILURE CODE [DD13KA] 1628
FAILURE CODE [DD13KB] 1630
FAILURE CODE [DD14KA] 1632
FAILURE CODE [DD14KB] 1634
FAILURE CODE [DDKAKA] 1636
FAILURE CODE [DDKAKB] 1638
FAILURE CODE [DDKFL4] 1640
FAILURE CODE [DDKGL4] 1642
FAILURE CODE [DDKHKA] 1644
FAILURE CODE [DDKHKB] 1646
FAILURE CODE [DDNLKA] 1648
FAILURE CODE [DDNLKB] 1650
FAILURE CODE [DDP6KA] 1652
FAILURE CODE [DDP6KB] 1655
FAILURE CODE [DDP6MA] 1657
FAILURE CODE [DDU1FS] 1659
FAILURE CODE [DDU1KA] 1661
FAILURE CODE [DDU1KY] 1664
FAILURE CODE [DFA4KX] 1666
FAILURE CODE [DFA4KZ] 1667
FAILURE CODE [DFA4L8] 1668
FAILURE CODE [DFA5KA] 1669
FAILURE CODE [DFA5KB] 1672
FAILURE CODE [DFA6KA] 1675
FAILURE CODE [DFA6KB] 1678
FAILURE CODE [DFA7KX] 1681
FAILURE CODE [DFA7KZ] 1682
FAILURE CODE [DFA7L8] 1683
FAILURE CODE [DFA8KA] 1684
FAILURE CODE [DFA8KB] 1687
FAILURE CODE [DFA9KA] 1690
FAILURE CODE [DFA9KB] 1693
FAILURE CODE [DGS1KA] 1696
FAILURE CODE [DGS1KX] 1699
FAILURE CODE [DH21KA] 1700
FAILURE CODE [DH21KB] 1702
FAILURE CODE [DHA4KA] 1704
FAILURE CODE [DHAAMA] 1706
FAILURE CODE [DHACMA] 1708
FAILURE CODE [DHH7KA] 1710
FAILURE CODE [DHH7KB] 1713
FAILURE CODE [DHH8KA] 1715
FAILURE CODE [DHH8KB] 1718
FAILURE CODE [DHH9KA] 1720
FAILURE CODE [DHH9KB] 1723
FAILURE CODE [DHHAKA] 1725
FAILURE CODE [DHHAKB] 1728
FAILURE CODE [DK30KA] 1730
FAILURE CODE [DK30KB] 1733
FAILURE CODE [DK30KX] 1735
FAILURE CODE [DK30KZ] 1736
FAILURE CODE [DK30L8] 1737
FAILURE CODE [DK31KA] 1738
FAILURE CODE [DK31KB] 1741
FAILURE CODE [DK40KA] 1743
FAILURE CODE [DK40KB] 1746
FAILURE CODE [DK55KX] 1748
FAILURE CODE [DK55KZ] 1749
FAILURE CODE [DK55L8] 1750
FAILURE CODE [DK56KA] 1751
FAILURE CODE [DK56KB] 1754
FAILURE CODE [DK57KA] 1756
FAILURE CODE [DK57KB] 1759
FAILURE CODE [DLM0KX] 1761
FAILURE CODE [DLM1KA] 1762
FAILURE CODE [DLM1KB] 1764
FAILURE CODE [DLM1MA] 1766
FAILURE CODE [DLM2KA] 1767
FAILURE CODE [DLM2KB] 1769
FAILURE CODE [DLM2MA] 1771
FAILURE CODE [DLM3KA] 1772
FAILURE CODE [DLM3KB] 1774
FAILURE CODE [DLM3MB] 1776
FAILURE CODE [DN21FS] 1777
FAILURE CODE [DR21KX] 1779
FAILURE CODE [DR31KX] 1780
FAILURE CODE [DV20KB] 1781
FAILURE CODE [DW4BKA] 1783
FAILURE CODE [DW4BKB] 1785
FAILURE CODE [DW4BKY] 1787
FAILURE CODE [DW7BKA] 1789
FAILURE CODE [DW7BKB] 1791
FAILURE CODE [DW7EKA] 1793
FAILURE CODE [DW7EKB] 1795
FAILURE CODE [DW7EKY] 1797
FAILURE CODE [DWN5KA] 1799
FAILURE CODE [DWN5KB] 1801
FAILURE CODE [DWN5KY] 1803
FAILURE CODE [DXA4KA] 1805
FAILURE CODE [DXA4KB] 1807
FAILURE CODE [DXA4KY] 1809
FAILURE CODE [DXA5KA] 1811
FAILURE CODE [DXA5KB] 1813
FAILURE CODE [DXA5KY] 1815
FAILURE CODE [DXA6KA] 1817
FAILURE CODE [DXA6KB] 1819
FAILURE CODE [DXA6KY] 1821
FAILURE CODE [DXA7KA] 1823
FAILURE CODE [DXA7KB] 1825
FAILURE CODE [DXA7KY] 1827
FAILURE CODE [DXHRKA] 1829
FAILURE CODE [DXHRKB] 1831
FAILURE CODE [DXHRKY] 1833
FAILURE CODE [DXHSKA] 1835
FAILURE CODE [DXHSKB] 1837
FAILURE CODE [DXHSKY] 1839
FAILURE CODE [DXHTKA] 1841
FAILURE CODE [DXHTKB] 1843
FAILURE CODE [DXHTKY] 1845
FAILURE CODE [DXHUKA] 1847
FAILURE CODE [DXHUKB] 1849
FAILURE CODE [DXHUKY] 1851
FAILURE CODE [DXJ4KA] 1853
FAILURE CODE [DXJ4KB] 1855
FAILURE CODE [DXJCKA] 1857
FAILURE CODE [DXJCKB] 1859
FAILURE CODE [DXJCKY] 1861
FAILURE CODE [DXJDKA] 1863
FAILURE CODE [DXJDKB] 1865
FAILURE CODE [DXJDKY] 1867
FAILURE CODE [DXK1KA] 1869
FAILURE CODE [DXK1KB] 1871
FAILURE CODE [DXK1KY] 1873
FAILURE CODE [DXK2KA] 1875
FAILURE CODE [DXK2KB] 1877
FAILURE CODE [DXK2KY] 1879
FAILURE CODE [F313KA] 1881
FAILURE CODE [F313KB] 1882
FAILURE CODE [F318KB] 1883
FAILURE CODE [F318KY] 1884
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1885
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1885
MANUAL PREHEATING SYSTEM DOES NOT WORK .1892
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1895
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1897
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1899
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP .1903
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1904
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1905
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1906
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1907
HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1908
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1909
HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1910
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .1911
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .1912
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1915
OPERATION MODE DOES NOT CHANGE .1916
OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN .1917
MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE .1918
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1919
SERVICE MODE CANNOT BE SELECTED 1920
WORK EQUIPMENT DOES NOT OPERATE 1921
FOOT HEATER DOES NOT OPERATE .1923
HORN DOES NOT SOUND 1929
HORN DOES NOT STOP SOUNDING 1931
BACKUP ALARM DOES NOT SOUND 1932
BACKUP ALARM DOES NOT STOP SOUNDING 1933
HEADLAMP DOES NOT LIGHT UP .1934
REAR LAMP DOES NOT LIGHT UP 1938
ALL WIPERS DO NOT OPERATE 1941
FRONT WIPER DOES NOT OPERATE .1943
REAR WIPER DOES NOT OPERATE 1945
LEFT DOOR WIPER DOES NOT OPERATE .1947
RIGHT DOOR WIPER DOES NOT OPERATE 1951
FRONT WASHER DOES NOT OPERATE 1955
REAR WASHER DOES NOT OPERATE .1957
LEFT DOOR WASHER DOES NOT OPERATE 1959
RIGHT DOOR WASHER DOES NOT OPERATE .1961
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1963
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1964
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1964
FAILURE MODE AND CAUSE TABLE .1965
NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) .1971
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) 1973
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) 1975
TRAVEL SPEED OR POWER IS LOW .1977
SPEED RANGE DOES NOT CHANGE 1979
SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS .1980
MACHINE DEVIATES LARGELY .1981
MACHINE DRIFT ON A SLOPE IS LARGE 1984
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .1986
UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR .1988
HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH .1990
ALL WORK EQUIPMENT DO NOT OPERATE 1992
ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 1994
BLADE LIFT SPEED OR POWER IS LOW .1995
BLADE TILT SPEED OR POWER IS LOW .1997
BLADE ANGLE SPEED OR POWER IS LOW 1998
TIME LAG OF BLADE LIFT IS LARGE 1999
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE .2000
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE .2001
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 2002
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .2003
UNUSUAL NOISE IS HEARD FROM AROUND FAN .2005
TROUBLESHOOTING OF ENGINE (S-MODE) .2006
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2006
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .2007
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .2008
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .2009
ENGINE STARTABILITY IS POOR 2011
ENGINE DOES NOT PICK UP SMOOTHLY .2013
ENGINE STOPS DURING OPERATION 2015
ENGINE RUNS ROUGH OR IS UNSTABLE .2017
ENGINE LACKS POWER .2018
KDPF GETS CLOGGED IN A SHORT TIME 2020
ENGINE OIL CONSUMPTION IS EXCESSIVE 2022
OIL BECOMES CONTAMINATED QUICKLY .2023
FUEL CONSUMPTION IS EXCESSIVE 2024
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2025
OIL PRESSURE DROPS .2026
FUEL MIXES INTO ENGINE OIL .2028
WATER MIXES INTO ENGINE OIL (MILKY) 2029
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2030
UNUSUAL NOISE IS HEARD .2031
VIBRATION IS EXCESSIVE .2032
AIR CANNOT BE BLED FROM FUEL CIRCUIT .2033
ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2034
ACTIVE REGENERATION TAKES TIME .2036
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2037
AdBlue/DEF CONSUMPTION IS EXCESSIVE 2038
THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2040
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2041
50 DISASSEMBLY AND ASSEMBLY 2043
CONTENTS .2044
ABBREVIATION LIST 2049
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2055
HOW TO READ THIS MANUAL 2055
COATING MATERIALS LIST .2057
SPECIAL TOOLS LIST .2061
SKETCHES OF SPECIAL TOOLS 2080
ENGINE AND COOLING SYSTEM 2093
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2093
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .2094
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .2099
REMOVE AND INSTALL INJECTOR ASSEMBLY .2106
METHOD FOR REMOVING INJECTOR ASSEMBLY 2106
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2113
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2123
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .2123
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2135
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2153
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2153
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2154
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2156
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2156
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2158
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2161
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2161
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2163
REMOVE AND INSTALL ALTERNATOR BELT .2165
METHOD FOR REMOVING ALTERNATOR BELT 2165
METHOD FOR INSTALLING ALTERNATOR BELT 2166
REMOVE AND INSTALL AUTOMATIC TENSIONER .2168
METHOD FOR REMOVING AUTOMATIC TENSIONER 2168
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2168
REMOVE AND INSTALL RADIATOR ASSEMBLY .2169
METHOD FOR REMOVING RADIATOR ASSEMBLY 2169
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2172
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2176
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2176
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2179
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2182
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2182
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2185
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2189
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY .2189
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY .2192
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2196
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY .2196
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY .2199
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY .2203
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY 2203
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY 2212
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2223
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2223
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2224
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2226
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2226
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2228
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2231
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2231
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2234
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2238
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2238
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2244
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2250
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2250
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2256
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2262
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2262
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2263
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2266
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2266
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2267
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2274
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2274
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2275
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2276
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER .2276
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER .2277
REMOVE AND INSTALL KDPF ASSEMBLY .2280
METHOD FOR REMOVING KDPF ASSEMBLY 2281
METHOD FOR INSTALLING KDPF ASSEMBLY 2284
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2287
METHOD FOR DISASSEMBLING KDPF ASSEMBLY .2287
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2290
REMOVE AND INSTALL SCR ASSEMBLY 2297
METHOD FOR REMOVING SCR ASSEMBLY .2297
METHOD FOR INSTALLING SCR ASSEMBLY .2299
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2303
METHOD FOR REMOVING KDPF, SCR ASSEMBLY .2304
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY .2310
REMOVE AND INSTALL KCCV ASSEMBLY .2317
METHOD FOR REMOVING KCCV ASSEMBLY 2317
METHOD FOR INSTALLING KCCV ASSEMBLY 2319
REMOVE AND INSTALL VGT ASSEMBLY 2321
METHOD FOR REMOVING VGT ASSEMBLY .2321
METHOD FOR INSTALLING VGT ASSEMBLY .2323
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2326
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2327
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2329
REMOVE AND INSTALL AdBlue/DEF INJECTOR .2333
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2333
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2336
REMOVE AND INSTALL AdBlue/DEF PUMP .2340
METHOD FOR REMOVING AdBlue/DEF PUMP 2340
METHOD FOR INSTALLING AdBlue/DEF PUMP 2343
REMOVE AND INSTALL AdBlue/DEF HOSE .2346
METHOD FOR REMOVING AdBlue/DEF HOSE 2346
METHOD FOR INSTALLING AdBlue/DEF HOSE 2350
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2356
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .2356
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .2358
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2361
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2361
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2362
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2364
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .2364
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .2368
POWER TRAIN 2372
REMOVE AND INSTALL DAMPER ASSEMBLY .2372
METHOD FOR REMOVING DAMPER ASSEMBLY 2372
METHOD FOR INSTALLING DAMPER ASSEMBLY 2373
REMOVE AND INSTALL HST PUMP ASSEMBLY .2375
METHOD FOR REMOVING HST PUMP ASSEMBLY 2375
METHOD FOR INSTALLING HST PUMP ASSEMBLY 2377
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY 2379
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY .2379
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY .2382
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 0
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2386
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY .2391
UNDERCARRIAGE AND FRAME 2400
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2400
METHOD FOR REMOVING TRACK FRAME ASSEMBLY .2400
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY .2404
REMOVE AND INSTALL IDLER ASSEMBLY 2409
METHOD FOR REMOVING IDLER ASSEMBLY .2409
METHOD FOR INSTALLING IDLER ASSEMBLY .2411
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2413
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2413
METHOD FOR ASSEMBLING IDLER ASSEMBLY .2415
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2420
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY .2420
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY .2421
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY 2422
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY .2422
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY .2425
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY .2428
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2428
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2429
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY .2432
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY .2432
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2434
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY .2438
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2438
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2439
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY .2441
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY .2441
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2442
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2445
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY .2445
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY .2446
SEPARATE AND CONNECT TRACK ASSEMBLY 2448
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY .2448
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2449
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2450
METHOD FOR CONNECTING TRACK ASSEMBLY .2451
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2453
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY .2453
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY .2453
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2455
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2455
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY .2460
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2473
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2474
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .2475
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2490
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2491
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2492
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2499
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2500
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2502
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2506
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY .2506
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY .2508
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS .2511
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS 2511
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS 2511
REMOVE AND INSTALL SEGMENT TEETH .2513
METHOD FOR REMOVING SEGMENT TEETH 2513
METHOD FOR INSTALLING SEGMENT TEETH 2514
HYDRAULIC SYSTEM .2515
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .2515
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2516
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2520
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2525
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .2525
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .2530
WORK EQUIPMENT .2535
REMOVE AND INSTALL BLADE ASSEMBLY 2535
METHOD FOR REMOVING BLADE ASSEMBLY .2535
METHOD FOR INSTALLING BLADE ASSEMBLY .2537
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .2540
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2540
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2542
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2544
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2545
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2546
REMOVE AND INSTALL U-FRAME ASSEMBLY 2550
METHOD FOR REMOVING U-FRAME ASSEMBLY .2550
METHOD FOR INSTALLING U-FRAME ASSEMBLY .2552
CAB AND ITS ATTACHMENTS 2554
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .2554
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2554
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2561
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2568
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .2570
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .2570
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .2576
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2576
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2582
REMOVE AND INSTALL RECEIVER DRIER 2589
METHOD FOR REMOVING RECEIVER DRIER .2589
METHOD FOR INSTALLING RECEIVER DRIER .2590
REMOVE AND INSTALL OPERATOR’S SEAT .2593
METHOD FOR REMOVING OPERATOR’S SEAT 2593
METHOD FOR INSTALLING OPERATOR’S SEAT 2594
REMOVE AND INSTALL SEAT BELT .2595
METHOD FOR REMOVING SEAT BELT 2595
METHOD FOR INSTALLING SEAT BELT 2595
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 2597
METHOD FOR REMOVING FOOT HEATER ASSEMBLY .2597
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY .2599
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 2602
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY 2602
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY .2603
ELECTRICAL SYSTEM 2604
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2604
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .2604
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .2606
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY .2609
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2609
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2610
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2611
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY .2611
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY .2612
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2614
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .2614
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .2616
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2617
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .2617
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .2619
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2621
METHOD FOR REMOVING SCR TEMPERATURE SENSOR .2621
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR .2622
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .2624
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2624
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2625
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2626
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2626
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2627
REMOVE AND INSTALL COMMUNICATION TERMINAL 2628
REMOVE COMMUNICATION TERMINAL 2628
INSTALL COMMUNICATION TERMINAL .2631
60 MAINTENANCE STANDARD 2635
CONTENTS .2636
ABBREVIATION LIST 2638
ENGINE AND COOLING SYSTEM 2644
MAINTENANCE STANDARD OF ENGINE MOUNT .2644
MAINTENANCE STANDARD OF DAMPER .2645
MAINTENANCE STANDARD OF COOLING SYSTEM .2646
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2648
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2650
POWER TRAIN 2651
MAINTENANCE STANDARD OF HST PUMP .2651
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 2652
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 2653
MAINTENANCE STANDARD OF HST CHARGE PUMP 2654
MAINTENANCE STANDARD OF HST MOTOR 2656
MAINTENANCE STANDARD OF FINAL DRIVE 2657
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 2659
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE .2660
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2662
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE .2663
UNDERCARRIAGE AND FRAME 2665
MAINTENANCE STANDARD OF SUSPENSION .2665
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2667
MAINTENANCE STANDARD OF IDLER 2669
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2671
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2672
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2673
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2674
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE 2675
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2676
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE .2677
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE .2679
MAINTENANCE STANDARD OF SINGLE SHOE 2681
MAINTENANCE STANDARD OF SWAMP SHOE .2682
HYDRAULIC SYSTEM .2683
MAINTENANCE STANDARD OF HYDRAULIC TANK .2683
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2684
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP .2685
MAINTENANCE STANDARD OF CONTROL VALVE 2687
MAINTENANCE STANDARD OF RIPPER PPC VALVE .2694
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID .2696
MAINTENANCE STANDARD OF EPC VALVE 2697
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE 2698
MAINTENANCE STANDARD OF QUICK DROP VALVE .2699
WORK EQUIPMENT .2701
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT .2701
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT .2704
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 2705
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 2706
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER .2707
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER .2708
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER .2710
CAB AND ITS ATTACHMENTS 2711
MAINTENANCE STANDARD OF CAB MOUNT 2711
ELECTRICAL SYSTEM 2712
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 2712
80 APPENDIX 2713
CONTENTS .2714
ABBREVIATION LIST 2715
AIR CONDITIONER SYSTEM .2721
PRECAUTIONS FOR REFRIGERANT 2721
AIR CONDITIONER COMPONENT 2722
SPECIFICATIONS OF AIR CONDITIONER 2725
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2726
OUTLINE OF REFRIGERATION CYCLE .2727
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2729
AIR CONDITIONER UNIT .2729
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2729
FUNCTION OF AIR CONDITIONER UNIT .2730
COMPONENT PARTS OF AIR CONDITIONER UNIT 2731
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .2731
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2731
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT .2731
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2732
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2732
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2732
FUNCTION OF DUAL PRESSURE SWITCH .2733
FUNCTION OF PRESSURE SWITCH 2733
COMPRESSOR .2734
STRUCTURE OF COMPRESSOR 2734
SPECIFICATIONS OF COMPRESSOR .2734
FUNCTION OF COMPRESSOR .2734
CONDENSER 2735
STRUCTURE OF CONDENSER .2735
SPECIFICATIONS OF CONDENSER 2735
FUNCTION OF CONDENSER 2736
RECEIVER DRIER .2737
STRUCTURE OF RECEIVER DRIER 2737
SPECIFICATIONS OF RECEIVER DRIER .2737
FUNCTION OF RECEIVER DRIER .2737
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2739
CIRCUIT DIAGRAM OF AIR CONDITIONER .2742
AIR CONDITIONER SYSTEM DIAGRAM .2743
CONTROL FUNCTION OF AIR CONDITIONER 2744
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2745
TEST RELAYS 2749
METHOD FOR TESTING RELAYS 2749
AIR CONDITIONER TROUBLESHOOTING CHART 1 2751
AIR CONDITIONER TROUBLESHOOTING CHART 2 2752
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .2755
TROUBLESHOOTING FOR CONDENSER FAN 2757
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2760
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .2764
TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION .2767
TROUBLESHOOTING USING GAUGE PRESSURE .2771
CONNECTION OF SERVICE TOOL .2773
METHOD FOR CONNECTING SERVICE TOOL .2773
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2774
HANDLE COMPRESSOR OIL 2776
90 CIRCUIT DIAGRAMS 2779
CONTENTS .2780
ABBREVIATION LIST 2781
HYDRAULIC CIRCUIT DIAGRAM 2787
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2787
HYDRAULIC CIRCUIT DIAGRAM 2791
ELECTRICAL CIRCUIT DIAGRAM .2793
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .2793
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (1/14) 2797
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (2/14) 2799
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (3/14) 2801
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (4/14) 2803
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (5/14) 2805
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (6/14) 2807
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (7/14) 2809
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (8/14) 2811
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (9/14) 2813
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (10/14) .2815
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (11/14) .2817
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (12/14) .2819
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (13/14) .2821
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (14/14) .2823
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/16) .2825
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/16) .2827
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/16) .2829
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/16) .2831
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/16) .2833
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/16) .2835
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/16) .2837
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/16) .2839
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/16) .2841
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/16) 2843
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (11/16) 2845
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (12/16) 2847
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (13/16) 2849
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (14/16) 2851
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (15/16) 2853
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (16/16) 2855
INDEX .2857

DESCRIPTION:

Komatsu BULLDOZER D61EX-24,D61PX-24 Shop Manual KEBM657710 –  PDF DOWNLOAD

• D61EX-B60001 and up
• D61PX-B60001 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