Komatsu D375Ai Bulldozer Shop Manual SEN06653-01 – PDF DOWNLOAD 

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Komatsu D375Ai Bulldozer Shop Manual SEN06653-01 – PDF DOWNLOAD

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Komatsu D375Ai Bulldozer Shop Manual SEN06653-01 – PDF DOWNLOAD 

Language : English
Pages : 3496
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D375Ai Bulldozer Shop Manual SEN06653-01 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 26
FOREWORD, SAFETY, BASIC INFORMATION 32
HOW TO READ THE SHOP MANUAL 32
SAFETY NOTICE FOR OPERATION 34
PRECAUTIONS TO PREVENT FIRE 42
ACTIONS IF FIRE OCCURS 44
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 45
45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 45
PRECAUTIONS FOR ADDING 45
PRECAUTIONS FOR STORING 45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 45
THE OTHER PRECAUTIONS 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 50
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: D375AI-8 103
SPECIFICATIONS 105
SPECIFICATIONS: D375AI-8 105
WEIGHT TABLE 111
WEIGHT TABLE: D375AI-8 111
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 113
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 113
10 STRUCTURE AND FUNCTION 115
CONTENTS 116
ABBREVIATION LIST 120
BOOT-UP SYSTEM 126
SYSTEM OPERATING LAMP SYSTEM 126
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 126
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 126
BATTERY ISOLATOR 128
LAYOUT DRAWING OF BATTERY ISOLATOR 128
FUNCTION OF BATTERY ISOLATOR 128
ENGINE SYSTEM 130
LAYOUT DRAWING OF ENGINE SYSTEM 130
ENGINE CONTROL SYSTEM 132
LAYOUT OF ENGINE CONTROL SYSTEM 132
ENGINE CONTROL SYSTEM DIAGRAM 133
FUNCTION OF ENGINE CONTROL SYSTEM 133
AUTOMATIC IDLE STOP SYSTEM 134
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 134
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 134
COMPONENT PARTS OF ENGINE SYSTEM 137
DAMPER 137
VGT 139
EGR SYSTEM 143
EGR VALVE 145
EGR COOLER 147
KCCV SYSTEM 148
KCCV VENTILATOR 150
KDPF 152
FUEL SYSTEM 156
FUEL SYSTEM CIRCUIT DIAGRAM 156
FUNCTION OF FUEL SYSTEM 157
OPERATION OF FUEL SYSTEM 157
CRI SYSTEM 158
COOLING SYSTEM 162
LAYOUT DRAWING OF COOLING SYSTEM 162
SPECIFICATIONS OF COOLING SYSTEM 163
COMPONENT PARTS OF COOLING SYSTEM 164
COOLING FAN PUMP 164
COOLING FAN MOTOR 183
HYDRAULIC OIL COOLER BYPASS VALVE 190
CONTROL SYSTEM 191
LAYOUT DRAWING OF CONTROL SYSTEM 191
MACHINE MONITOR SYSTEM 192
MACHINE MONITOR SYSTEM DIAGRAM 192
FUNCTION OF MACHINE MONITOR SYSTEM 192
KOMTRAX Plus SYSTEM 195
KOMTRAX Plus SYSTEM DIAGRAM 195
FUNCTION OF KOMTRAX Plus SYSTEM 195
COMPONENT PARTS OF CONTROL SYSTEM 197
MACHINE MONITOR 197
KOMTRAX TERMINAL 214
KOMTRAX Plus CONTROLLER 216
WIRELESS LAN UNIT 221
POWER TRAIN CONTROLLER 222
WORK EQUIPMENT CONTROLLER 226
ENGINE CONTROLLER 230
OPTION CONTROLLER 243
FUEL FEED PUMP 247
FUEL FEED PUMP SWITCH 248
HYDRAULIC SYSTEM 249
LAYOUT DRAWING OF HYDRAULIC SYSTEM 249
CLSS 250
STRUCTURE OF CLSS 250
FUNCTION OF CLSS 251
COMPONENT PARTS OF HYDRAULIC SYSTEM 253
HYDRAULIC TANK 253
WORK EQUIPMENT PUMP 255
LS VALVE 259
PTO, TRANSMISSION LUBRICATION PUMP, AND POWER TRAIN PUMP 264
CONTROL VALVE 265
POWER TRAIN SYSTEM 285
LAYOUT OF POWER TRAIN SYSTEM 285
OPERATION OF POWER TRAIN SYSTEM 288
TRANSMISSION, STEERING, AND BRAKE CONTROL 289
LAYOUT OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM PARTS 289
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL 290
PALM COMMAND CONTROL SYSTEM 292
PALM COMMAND CONTROL SYSTEM DIAGRAM 292
CENTRALIZED PRESSURE PICKUP PORT 296
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT 296
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT 297
COMPONENT PARTS OF POWER TRAIN SYSTEM 298
UNIVERSAL JOINT 298
POWER TRAIN MOUNT 299
TORQUE CONVERTER AND PTO 300
TORQUE CONVERTER CONTROL VALVE 307
LOCKUP CLUTCH ECMV 309
STATOR CLUTCH ECMV 313
TRANSMISSION 317
TRANSMISSION ECMV 329
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 335
TRANSMISSION LUBRICATION RELIEF VALVE 337
TRANSFER AND BEVEL PINION 338
BEVEL GEAR SHAFT, STEERING CLUTCH, AND BRAKE 339
FINAL DRIVE 346
SCAVENGING PUMP 350
ELECTRIC STEERING CONTROL LEVER 351
WORK EQUIPMENT SYSTEM 355
WORK EQUIPMENT CONTROL 355
LAYOUT OF WORK EQUIPMENT CONTROL 355
WORK EQUIPMENT CONTROL FUNCTION 356
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 357
LAYOUT OF VARIABLE GIANT RIPPER 358
LAYOUT OF VARIABLE MULTI-SHANK RIPPER 359
SHOE SLIP CONTROL SYSTEM 360
FUNCTION OF SHOE SLIP CONTROL SYSTEM 360
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 361
SELF-PRESSURE REDUCING VALVE 361
WORK EQUIPMENT LOCK SOLENOID VALVE 366
PILOT CIRCUIT ACCUMULATOR 367
QUICK DROP VALVE 368
PISTON VALVE 370
ELECTRIC BLADE CONTROL LEVER 371
RIPPER ELECTRIC LEVER 372
PIN PULLER SWITCH 373
ICT SYSTEM 374
LAYOUT DRAWING OF ICT SYSTEM 374
ICT CONTROL SYSTEM DIAGRAM 375
BLADE CONTROL SYSTEM 377
FUNCTION OF BLADE CONTROL SYSTEM 377
LEVELING MODE SYSTEM DIAGRAM 379
FUNCTION OF LEVELING MODE 380
OPERATION OF LEVELING MODE 380
DOZING MODE SYSTEM DIAGRAM 381
FUNCTION OF DOZING MODE 381
OPERATION OF DOZING MODE 381
SMOOTH START SYSTEM 382
SMOOTH START SYSTEM DIAGRAM 382
FUNCTION OF SMOOTH START SYSTEM 382
OPERATION OF SMOOTH START SYSTEM 382
SLIP CONTROL SYSTEM 384
SLIP CONTROL SYSTEM DIAGRAM 384
FUNCTION OF SLIP CONTROL SYSTEM 384
OPERATION OF SLIP CONTROL SYSTEM 384
ASSIST CONTROL SYSTEM 386
ASSIST CONTROL SYSTEM DIAGRAM 386
FUNCTION OF ASSIST CONTROL SYSTEM 386
OPERATION OF ASSIST CONTROL SYSTEM 387
DIRECTION CONTROL SYSTEM 388
DIRECTION CONTROL SYSTEM DIAGRAM 388
FUNCTION OF DIRECTION CONTROL SYSTEM 389
OPERATION OF DIRECTION CONTROL SYSTEM 389
SMOOTH CARIY SYSTEM 390
SMOOTH CARIY SYSTEM DIAGRAM 390
FUNCTION OF SMOOTH CARIY SYSTEM 391
OPERATION OF SMOOTH CARIY SYSTEM 391
COMPONENT PARTS OF ICT SYSTEM 392
NAVIGATION CONTROLLER 392
CONTROL BOX 396
AUX BOX 398
IMU SENSOR 401
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER 404
LIFTING SYSTEM 406
POWER LADDER SYSTEM 406
DRAWING OF POWER LADDER SYSTEM 406
HYDRAULIC CIRCUIT DIAGRAM OF POWER LADDER SYSTEM 407
FUNCTION OF POWER LADDER SYSTEM 407
COMPONENT PARTS OF LIFTING SYSTEM 409
SWITCH BOX 409
POWER LADDER LIMIT SWITCH PART 410
CONTROL VALVE ASSEMBLY 411
RADIO CONTROL SYSTEM 412
LAYOUT DRAWING OF RADIO CONTROL SYSTEM 412
SPECIFICATIONS OF RADIO CONTROL SYSTEM 413
COMPONENT PARTS OF RADIO CONTROL SYSTEM 414
RADIO CONTROL TRANSMITTER 414
RADIO CONTROL RECEIVER 416
RADIO CONTROL ON-BOARD SELECTOR SWITCH 417
UNDERCARRIAGE AND FRAME 419
MAIN FRAME 419
STRUCTURE OF MAIN FRAME 419
SUSPENSION 421
STRUCTURE OF SUSPENSION 421
FUNCTION OF SUSPENSION 423
TRACK FRAME AND IDLER CUSHION 424
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 424
SPECIFICATIONS OF TRACK FRAME AND IDLER CUSHION 425
FUNCTION OF TRACK FRAME AND IDLER CUSHION 425
WORK EQUIPMENT 426
STRUCTURE OF FRONT WORK EQUIPMENT 426
STRUCTURE OF CYLINDER STAY 428
STRUCTURE OF VARIABLE GIANT RIPPER 429
STRUCTURE OF VARIABLE MULTI-SHANK RIPPER 430
CAB AND ITS ATTACHMENTS 431
ROPS 431
STRUCTURE OF ROPS 431
FUNCTION OF ROPS 431
CAB 432
STRUCTURE OF CAB 432
CAB MOUNT 433
STRUCTURE OF CAB MOUNT 433
20 STANDARD VALUE TABLE 435
CONTENTS 436
ABBREVIATION LIST 437
STANDARD VALUE TABLE FOR ENGINE 443
STANDARD VALUE TABLE FOR ENGINE: D375AI-8 443
STANDARD VALUE TABLE FOR MACHINE 449
STANDARD VALUE TABLE FOR MACHINE: D375AI-8 449
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 476
30 TESTING AND ADJUSTING 479
CONTENTS 480
ABBREVIATION LIST 484
RELATED INFORMATION ON TESTING AND ADJUSTING 490
TOOLS FOR TESTING AND ADJUSTING 490
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 496
ENGINE AND COOLING SYSTEM 498
TEST ENGINE SPEED 498
METHOD FOR TESTING ENGINE SPEED 498
TEST BOOST PRESSURE 502
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 502
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 503
TEST EXHAUST GAS TEMPERATURE 505
METHOD FOR TESTING EXHAUST TEMPERATURE BY MACHINE MONITOR 505
METHOD FOR TESTING EXHAUST TEMPERATURE BY TESTING TOOLS 506
TEST EXHAUST GAS COLOR 509
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 509
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 510
TEST AND ADJUST VALVE CLEARANCE 512
METHOD FOR TESTING VALVE CLEARANCE 512
METHOD FOR ADJUSTING VALVE CLEARANCE 513
TEST COMPRESSION PRESSURE 515
METHOD FOR TESTING COMPRESSION PRESSURE 515
TEST BLOWBY PRESSURE 519
METHOD FOR TESTING BLOWBY PRESSURE 519
TEST ENGINE OIL PRESSURE 521
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 521
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 521
TEST EGR VALVE AND VGT OIL PRESSURE 523
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 523
TEST FUEL PRESSURE 524
METHOD FOR TESTING FUEL PRESSURE 524
TEST FUEL RETURN RATE AND LEAKAGE 526
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 527
BLEED AIR FROM FUEL SYSTEM 532
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 532
TEST FUEL CIRCUIT FOR LEAKAGE 534
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 534
TEST SUPPLY PUMP 536
METHOD FOR TESTING SUPPLY PUMP 536
HANDLE CYLINDER CUT-OUT MODE OPERATION 539
HANDLE NO-INJECTION CRANKING OPERATION 540
CLEAN FUEL DOSER 541
METHOD FOR CLEANING FUEL DOSER 541
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 544
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 544
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 550
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 550
ADJUST DECELERATOR PEDAL 551
METHOD FOR ADJUSTING DECELERATOR PEDAL 551
POWER TRAIN 554
TEST POWER TRAIN OIL PRESSURE 554
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 555
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 571
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 571
TEST BRAKE PERFORMANCE SIMPLY 573
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 573
TEST AND ADJUST BRAKE PEDAL 574
METHOD FOR TESTING BRAKE PEDAL 574
METHOD FOR ADJUSTING BRAKE PEDAL 574
ADJUST PARKING BRAKE LEVER 577
METHOD FOR ADJUSTING PARKING BRAKE LEVER 577
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL 579
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 579
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM 580
UNDERCARRIAGE AND FRAME 583
TEST AND ADJUST TRACK TENSION 583
METHOD FOR TESTING TRACK TENSION 583
METHOD FOR ADJUSTING TRACK TENSION 583
HYDRAULIC SYSTEM 585
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 585
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 585
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 586
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 586
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 588
TEST OIL PRESSURE OF CONTROL CIRCUIT 589
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 589
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE 591
METHOD FOR TESTING WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE 591
TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE 593
METHOD FOR TESTING RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE 593
BLEED AIR FROM WORK EQUIPMENT PUMP 595
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT PUMP 595
TEST COOLING FAN SPEED 596
METHOD FOR TESTING COOLING FAN SPEED 596
TEST COOLING FAN CIRCUIT OIL PRESSURE 597
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 597
BLEED AIR FROM COOLING FAN PUMP 599
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP 599
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 600
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 600
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 600
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 601
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 602
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 602
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 604
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 604
OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE 605
METHOD FOR OPERATING WHEN WORK EQUIPMENT IS INOPERABLE 605
POWER LADDER 607
BLEED AIR FROM POWER LADDER CYLINDER 607
METHOD FOR BLEEDING AIR FROM POWER LADDER CYLINDERS 607
TESTING AND ADJUSTING OF POWER LADDER LIMIT SWITCH 612
METHOD FOR TESTING POWER LADDER LIMIT SWITCH 612
METHOD FOR ADJUSTING POWER LADDER LIMIT SWITCH 612
WORK EQUIPMENT 620
ADJUST WORK EQUIPMENT LOCK LEVER 620
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 620
CAB AND ITS ATTACHMENTS 622
TEST AND ADJUST OPERATOR’S CAB 622
METHOD FOR TESTING OPERATOR’S CAB 622
METHOD FOR ADJUSTING OPERATOR’S CAB 625
ADJUST RATTLING OPERATOR’S SEAT 628
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 628
ELECTRICAL SYSTEM 629
SET AND OPERATE MACHINE MONITOR 629
OPERATOR MODE 632
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 632
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 632
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 633
CHECKING FUNCTION OF SERVICE METER 634
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 634
SERVICE MODE 636
METHOD FOR OPERATING SERVICE MODE 636
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 638
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 644
ABNORMALITY RECORD MENU 657
METHOD FOR CONFIRMING MAINTENANCE RECORD 662
METHOD FOR OPERATING MAINTENANCE MODE SETTING 663
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 666
DEFAULT MENU 667
DIAGNOSTIC TESTS MENU 676
ADJUSTMENT MENU 686
METHOD FOR PERFORMING NO-INJECTION CRANKING 773
KOMTRAX SETTINGS MENU 775
METHOD FOR DISPLAYING SERVICE MESSAGE 777
METHOD FOR HANDLING SNAP SHOT 778
METHOD FOR STARTING UP KOMTRAX TERMINAL 780
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 785
METHOD FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 785
SETTING DEFAULT OF WIRELESS LAN MODEM 788
METHOD FOR SETTING DEFAULT OF WIRELESS LAN MODEM 788
METHOD FOR CHECKING OF WIRELESS LAN MODEM COMMUNICATION 789
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA 790
METHOD FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA 790
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 793
METHOD FOR ADJUSTING WHEN KOMTRAX Plus CONTROLLER IS REPLACED 793
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 796
METHOD FOR ADJUSTING WHEN WIRELESS LAN MODEM IS REPLACED 796
ADJUST REARVIEW CAMERA ANGLE 799
ADJUST REARVIEW CAMERA ANGLE 799
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 800
HANDLE BATTERY DISCONNECT SWITCH 801
HANDLE BATTERY ISOLATOR AND STARTING MOTOR ISOLATOR 802
TEST DIODES 803
METHOD FOR TESTING DIODE USING DIGITAL TESTER 803
METHOD FOR TESTING DIODE USING ANALOG TESTER 803
ICT SYSTEM 804
SET AND OPERATE CONTROL BOX 804
TEST AND ADJUST ICT RELATED DEVICES 804
CALIBRATE BLADE EDGE POSITION 809
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A) 809
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B) 815
CALIBRATE IMU SENSOR 831
METHOD FOR CALIBRATING IMU SENSOR 831
RESET CYLINDER STROKE END 836
RESET LIFT CYLINDER STROKE END 836
SET STANDARD ANGLE OF BLADE EDGE 839
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE 841
CHECK BLADE ELEVATION, ADJUST 844
CHECK BLADE ELEVATION 844
ADJUST BLADE ELEVATION 848
TEST STROKE SENSOR FOR LIFT CYLINDER 850
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER 850
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER 854
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER 854
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER 855
ADJUST WHEN WORK EQUIPMENT CONTROLLER IS REPLACED 856
METHOD FOR ADJUSTING WHEN WORK EQUIPMENT CONTROLLER IS REPLACED 856
ADJUST WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED 859
RADIO CONTROL 863
ID SETUP 863
METHOD FOR SETTING RADIO CONTROL TRANSMITTER ID 863
METHOD FOR SETTING RADIO CONTROL RECEIVER ID 864
Pm CLINIC 867
Pm CLINIC SERVICE 867
Pm CLINIC CHECK SHEET:D375AI-8 868
PM CLINIC CHECK SHEET FOR UNDERCARRIAGE: D375AI-8 889
PERFORMING QUICK Pm 894
METHOD FOR PERFORMING QUICK Pm 894
40 TROUBLESHOOTING 899
CONTENTS 900
ABBREVIATION LIST 914
RELATED INFORMATION ON TROUBLESHOOTING 920
GENERAL TROUBLESHOOTING POINTS 920
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM 921
SEQUENCE OF EVENTS IN TROUBLESHOOTING 928
TROUBLESHOOTING FOR RADIO CONTROL SYSTEM 930
CHECKS BEFORE TROUBLESHOOTING (SPECIFICATIONS OF RADIO CONTROL) 930
TEST OPERATING STATE OF RADIO CONTROL RECEIVER 931
TEST OPERATING STATE OF RADIO CONTROL TRANSMITTER 932
CHECKS BEFORE TROUBLESHOOTING 933
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 935
WALK-AROUND CHECK 935
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 937
METHOD FOR DRAINING WATER AND SEDIMENT FROM FUEL TANK 937
METHOD FOR CHECKING WATER SEPARATOR, DRAINING WATER AND SEDIMENT 937
MAIN FILTER – CHECK 938
METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL 939
METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT 941
METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL 942
METHOD FOR CHECKING OIL LEVEL IN POWER TRAIN CASE AND ADDING OIL 943
METHOD FOR CHECKING DUST INDICATOR 944
METHOD FOR CHECKING BRAKE OPERATION 945
METHOD FOR CHECKING ELECTRIC WIRING 945
METHOD FOR CHECKING FUEL LEVEL, ADDING FUEL 945
METHOD FOR CHECKING LAMPS OPERATION 946
METHOD FOR CHECKING MACHINE MONITOR 946
METHOD FOR REMOVING DEPOSIT IN ENGINE COMPARTMENT 947
METHOD FOR CHECKING HORN OPERATION 947
METHOD FOR CHECKING BACKUP ALARM OPERATION STATUS 948
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 948
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 953
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 953
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 953
PREPARATION FOR TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER 953
PREPARATION FOR TROUBLESHOOTING OF POWER TRAIN CONTROLLER 954
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL 954
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK 954
PROCEDURE FOR TESTING AND TROUBLESHOOTING 959
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 962
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 965
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 967
CONNECTOR LIST AND LAYOUT 970
CONNECTOR CONTACT IDENTIFICATION 993
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1033
FUSE LOCATION TABLE 1039
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1043
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135]) 1047
FAILURE CODES TABLE 1049
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1076
FAILURE CODE [1500L0] 1076
FAILURE CODE [15B0NX] 1077
FAILURE CODE [15SAL1] 1079
FAILURE CODE [15SALH] 1081
FAILURE CODE [15SBL1] 1083
FAILURE CODE [15SBLH] 1085
FAILURE CODE [15SEL1] 1087
FAILURE CODE [15SELH] 1089
FAILURE CODE [15SFL1] 1091
FAILURE CODE [15SFLH] 1093
FAILURE CODE [15SGL1] 1095
FAILURE CODE [15SGLH] 1097
FAILURE CODE [15SJL1] 1099
FAILURE CODE [15SJLH] 1101
FAILURE CODE [1800MW] 1103
FAILURE CODE [2201L1] 1104
FAILURE CODE [2201LH] 1106
FAILURE CODE [2202L1] 1108
FAILURE CODE [2202LH] 1109
FAILURE CODE [2300NR] 1111
FAILURE CODE [2301L1] 1112
FAILURE CODE [2301LH] 1114
FAILURE CODE [2301NR] 1116
FAILURE CODE [2301NT] 1117
FAILURE CODE [2302L1] 1118
FAILURE CODE [2302LH] 1120
FAILURE CODE [2302NR] 1122
FAILURE CODE [2302NT] 1123
FAILURE CODE [851PKA] 1124
FAILURE CODE [851QKA] 1125
FAILURE CODE [851RKA] 1126
FAILURE CODE [851SKA] 1127
FAILURE CODE [851TKA] 1128
FAILURE CODE [851UKA] 1129
FAILURE CODE [851VKA] 1130
FAILURE CODE [851XKA] 1131
FAILURE CODE [852RKR] 1132
FAILURE CODE [8590KA] 1133
FAILURE CODE [8590KY] 1138
FAILURE CODE [879AKA] 1141
FAILURE CODE [879AKB] 1142
FAILURE CODE [879BKA] 1143
FAILURE CODE [879BKB] 1145
FAILURE CODE [879CKA] 1147
FAILURE CODE [879CKB] 1148
FAILURE CODE [879DKZ] 1149
FAILURE CODE [879EMC] 1151
FAILURE CODE [879FMC] 1152
FAILURE CODE [879GKX] 1153
FAILURE CODE [989L00] 1155
FAILURE CODE [989M00] 1156
FAILURE CODE [989N00] 1157
FAILURE CODE [A1U0N3] 1158
FAILURE CODE [A1U0N4] 1160
FAILURE CODE [A900FR] 1162
FAILURE CODE [A900N6] 1163
FAILURE CODE [A900NY] 1164
FAILURE CODE [AA10NX] 1165
FAILURE CODE [AB00KE] 1167
FAILURE CODE [AQ00N3] 1169
FAILURE CODE [AQ00N4] 1170
FAILURE CODE [AQ10N3] 1171
FAILURE CODE [B@BAZG] 1172
FAILURE CODE [B@BAZK] 1173
FAILURE CODE [B@BCNS] 1174
FAILURE CODE [B@BCZK] 1175
FAILURE CODE [B@CENS] 1177
FAILURE CODE [B@HANS] 1179
FAILURE CODE [B@HAZK] 1181
FAILURE CODE [CA115] 1182
FAILURE CODE [CA122] 1186
FAILURE CODE [CA123] 1188
FAILURE CODE [CA131] 1190
FAILURE CODE [CA132] 1192
FAILURE CODE [CA135] 1194
FAILURE CODE [CA141] 1196
FAILURE CODE [CA144] 1198
FAILURE CODE [CA145] 1200
FAILURE CODE [CA153] 1202
FAILURE CODE [CA154] 1204
FAILURE CODE [CA187] 1206
FAILURE CODE [CA212] 1208
FAILURE CODE [CA213] 1210
FAILURE CODE [CA221] 1212
FAILURE CODE [CA222] 1214
FAILURE CODE [CA227] 1216
FAILURE CODE [CA234] 1218
FAILURE CODE [CA238] 1219
FAILURE CODE [CA239] 1221
FAILURE CODE [CA271] 1223
FAILURE CODE [CA272] 1225
FAILURE CODE [CA273] 1226
FAILURE CODE [CA274] 1228
FAILURE CODE [CA322] 1229
FAILURE CODE [CA323] 1231
FAILURE CODE [CA324] 1233
FAILURE CODE [CA325] 1235
FAILURE CODE [CA331] 1237
FAILURE CODE [CA332] 1239
FAILURE CODE [CA343] 1241
FAILURE CODE [CA351] 1243
FAILURE CODE [CA352] 1245
FAILURE CODE [CA356] 1247
FAILURE CODE [CA357] 1249
FAILURE CODE [CA386] 1251
FAILURE CODE [CA441] 1253
FAILURE CODE [CA442] 1255
FAILURE CODE [CA449] 1257
FAILURE CODE [CA451] 1258
FAILURE CODE [CA452] 1260
FAILURE CODE [CA515] 1262
FAILURE CODE [CA516] 1263
FAILURE CODE [CA553] 1264
FAILURE CODE [CA555] 1265
FAILURE CODE [CA556] 1267
FAILURE CODE [CA559] 1269
FAILURE CODE [CA595] 1274
FAILURE CODE [CA687] 1276
FAILURE CODE [CA689] 1278
FAILURE CODE [CA691] 1280
FAILURE CODE [CA692] 1282
FAILURE CODE [CA697] 1284
FAILURE CODE [CA698] 1285
FAILURE CODE [CA731] 1286
FAILURE CODE [CA778] 1290
FAILURE CODE [CA1117] 1292
FAILURE CODE [CA1135] 1294
FAILURE CODE [CA1257] 1297
FAILURE CODE [CA1664] 1298
FAILURE CODE [CA1691] 1300
FAILURE CODE [CA1695] 1303
FAILURE CODE [CA1696] 1305
FAILURE CODE [CA1843] 1307
FAILURE CODE [CA1844] 1309
FAILURE CODE [CA1879] 1311
FAILURE CODE [CA1881] 1313
FAILURE CODE [CA1883] 1315
FAILURE CODE [CA1921] 1318
FAILURE CODE [CA1922] 1320
FAILURE CODE [CA1923] 1324
FAILURE CODE [CA1924] 1326
FAILURE CODE [CA1925] 1328
FAILURE CODE [CA1927] 1330
FAILURE CODE [CA1928] 1332
FAILURE CODE [CA1942] 1334
FAILURE CODE [CA1963] 1336
FAILURE CODE [CA1977] 1340
FAILURE CODE [CA1993] 1342
FAILURE CODE [CA2185] 1345
FAILURE CODE [CA2186] 1347
FAILURE CODE [CA2249] 1349
FAILURE CODE [CA2265] 1354
FAILURE CODE [CA2266] 1356
FAILURE CODE [CA2271] 1358
FAILURE CODE [CA2272] 1360
FAILURE CODE [CA2349] 1362
FAILURE CODE [CA2353] 1364
FAILURE CODE [CA2357] 1366
FAILURE CODE [CA2381] 1369
FAILURE CODE [CA2382] 1371
FAILURE CODE [CA2383] 1373
FAILURE CODE [CA2386] 1375
FAILURE CODE [CA2387] 1377
FAILURE CODE [CA2637] 1380
FAILURE CODE [CA2639] 1383
FAILURE CODE [CA2732] 1385
FAILURE CODE [CA2733] 1387
FAILURE CODE [CA2741] 1389
FAILURE CODE [CA2765] 1390
FAILURE CODE [CA2777] 1391
FAILURE CODE [CA2878] 1393
FAILURE CODE [CA2881] 1396
FAILURE CODE [CA3133] 1399
FAILURE CODE [CA3134] 1401
FAILURE CODE [CA3135] 1403
FAILURE CODE [CA3167] 1406
FAILURE CODE [CA3251] 1409
FAILURE CODE [CA3253] 1411
FAILURE CODE [CA3254] 1416
FAILURE CODE [CA3255] 1419
FAILURE CODE [CA3256] 1422
FAILURE CODE [CA3311] 1424
FAILURE CODE [CA3312] 1426
FAILURE CODE [CA3313] 1428
FAILURE CODE [CA3314] 1429
FAILURE CODE [CA3315] 1430
FAILURE CODE [CA3316] 1433
FAILURE CODE [CA3317] 1434
FAILURE CODE [CA3318] 1435
FAILURE CODE [CA3319] 1438
FAILURE CODE [CA3321] 1439
FAILURE CODE [CA3322] 1440
FAILURE CODE [CA3419] 1443
FAILURE CODE [CA3421] 1445
FAILURE CODE [CA4151] 1447
FAILURE CODE [CA4158] 1451
FAILURE CODE [CA4161] 1452
FAILURE CODE [CA4162] 1454
FAILURE CODE [CA4163] 1456
FAILURE CODE [CA4259] 1458
FAILURE CODE [CA4952] 1461
FAILURE CODE [CA5383] 1463
FAILURE CODE [CB115] 1464
FAILURE CODE [CB187] 1467
FAILURE CODE [CB227] 1469
FAILURE CODE [CB238] 1470
FAILURE CODE [CB239] 1472
FAILURE CODE [CB271] 1474
FAILURE CODE [CB272] 1476
FAILURE CODE [CB273] 1477
FAILURE CODE [CB274] 1479
FAILURE CODE [CB343] 1480
FAILURE CODE [CB352] 1482
FAILURE CODE [CB386] 1484
FAILURE CODE [CB441] 1486
FAILURE CODE [CB442] 1488
FAILURE CODE [CB689] 1490
FAILURE CODE [CB697] 1492
FAILURE CODE [CB698] 1493
FAILURE CODE [CB731] 1494
FAILURE CODE [CB778] 1498
FAILURE CODE [CB1117] 1500
FAILURE CODE [CB1257] 1502
FAILURE CODE [CB1664] 1503
FAILURE CODE [CB1691] 1505
FAILURE CODE [CB1695] 1508
FAILURE CODE [CB1696] 1510
FAILURE CODE [CB1879] 1512
FAILURE CODE [CB1881] 1514
FAILURE CODE [CB1883] 1516
FAILURE CODE [CB1921] 1519
FAILURE CODE [CB1922] 1521
FAILURE CODE [CB1923] 1525
FAILURE CODE [CB1924] 1527
FAILURE CODE [CB1925] 1529
FAILURE CODE [CB1927] 1531
FAILURE CODE [CB1928] 1533
FAILURE CODE [CB1963] 1535
FAILURE CODE [CB1977] 1539
FAILURE CODE [CB1993] 1541
FAILURE CODE [CB2265] 1544
FAILURE CODE [CB2266] 1546
FAILURE CODE [CB2637] 1548
FAILURE CODE [CB2639] 1551
FAILURE CODE [CB2732] 1553
FAILURE CODE [CB2733] 1555
FAILURE CODE [CB2741] 1557
FAILURE CODE [CB2777] 1559
FAILURE CODE [CB2878] 1561
FAILURE CODE [CB2881] 1564
FAILURE CODE [CB3133] 1567
FAILURE CODE [CB3134] 1569
FAILURE CODE [CB3135] 1571
FAILURE CODE [CB3167] 1574
FAILURE CODE [CB3251] 1577
FAILURE CODE [CB3253] 1579
FAILURE CODE [CB3254] 1584
FAILURE CODE [CB3255] 1587
FAILURE CODE [CB3256] 1590
FAILURE CODE [CB3311] 1592
FAILURE CODE [CB3312] 1594
FAILURE CODE [CB3313] 1596
FAILURE CODE [CB3314] 1597
FAILURE CODE [CB3315] 1598
FAILURE CODE [CB3316] 1601
FAILURE CODE [CB3317] 1602
FAILURE CODE [CB3318] 1603
FAILURE CODE [CB3319] 1606
FAILURE CODE [CB3321] 1607
FAILURE CODE [CB3322] 1608
FAILURE CODE [CB4151] 1611
FAILURE CODE [CB4158] 1615
FAILURE CODE [CB4161] 1616
FAILURE CODE [CB4162] 1618
FAILURE CODE [CB4163] 1620
FAILURE CODE [CB4259] 1623
FAILURE CODE [CB4952] 1626
FAILURE CODE [CB5383] 1628
FAILURE CODE [D130KA] 1629
FAILURE CODE [D130KB] 1631
FAILURE CODE [D141KA] 1632
FAILURE CODE [D141KB] 1634
FAILURE CODE [D141KY] 1636
FAILURE CODE [D162KA] 1638
FAILURE CODE [D162KB] 1640
FAILURE CODE [D162KY] 1642
FAILURE CODE [D16CKA] 1644
FAILURE CODE [D16CKB] 1646
FAILURE CODE [D16CKY] 1647
FAILURE CODE [D182KZ] 1649
FAILURE CODE [D19CKA] 1651
FAILURE CODE [D19CKB] 1653
FAILURE CODE [D19CKY] 1655
FAILURE CODE [D19EKA] 1657
FAILURE CODE [D19EKB] 1659
FAILURE CODE [D19EKY] 1661
FAILURE CODE [D19FKA] 1663
FAILURE CODE [D19FKB] 1665
FAILURE CODE [D19FKY] 1667
FAILURE CODE [D19GKA] 1669
FAILURE CODE [D19GKB] 1671
FAILURE CODE [D19GKY] 1673
FAILURE CODE [D19JKZ] 1675
FAILURE CODE [D1D5KA] 1677
FAILURE CODE [D1D5KB] 1679
FAILURE CODE [D1D5KY] 1681
FAILURE CODE [D1EFKA] 1682
FAILURE CODE [D1EFKB] 1684
FAILURE CODE [D1EWKA] 1686
FAILURE CODE [D1EWKB] 1687
FAILURE CODE [D1EWKY] 1688
FAILURE CODE [D862KA] 1689
FAILURE CODE [DAF0MB] 1690
FAILURE CODE [DAF0MC] 1691
FAILURE CODE [DAF8KB] 1692
FAILURE CODE [DAF9KQ] 1693
FAILURE CODE [DAFGMC] 1694
FAILURE CODE [DAFLKA] 1695
FAILURE CODE [DAFLKB] 1698
FAILURE CODE [DAFQKR] 1700
FAILURE CODE [DAQW00] 1705
FAILURE CODE [DAZ9KQ] 1706
FAILURE CODE [DAZQKR] 1707
FAILURE CODE [DB2QKR] 1711
FAILURE CODE [DB2RKR] 1717
FAILURE CODE [DB90KT] 1722
FAILURE CODE [DB90MC] 1723
FAILURE CODE [DB91KK] 1724
FAILURE CODE [DB92KK] 1727
FAILURE CODE [DB95KK] 1730
FAILURE CODE [DB97KK] 1732
FAILURE CODE [DB99KQ] 1734
FAILURE CODE [DB9LKA] 1735
FAILURE CODE [DB9LKB] 1737
FAILURE CODE [DB9QKR] 1739
FAILURE CODE [DB9RKR] 1744
FAILURE CODE [DBE0KT] 1749
FAILURE CODE [DBE0MC] 1750
FAILURE CODE [DBE1KK] 1751
FAILURE CODE [DBE2KK] 1754
FAILURE CODE [DBE5KK] 1757
FAILURE CODE [DBE6KK] 1759
FAILURE CODE [DBE9KQ] 1761
FAILURE CODE [DBELKA] 1762
FAILURE CODE [DBELKB] 1765
FAILURE CODE [DBEQKR] 1767
FAILURE CODE [DBERKR] 1772
FAILURE CODE [DBU0KR] 1777
FAILURE CODE [DBUSKR] 1778
FAILURE CODE [DBUTKA] 1779
FAILURE CODE [DBUTKN] 1780
FAILURE CODE [DBV0MC] 1781
FAILURE CODE [DBV1KK] 1782
FAILURE CODE [DBVLKA] 1784
FAILURE CODE [DBVLKB] 1786
FAILURE CODE [DBVQKR] 1788
FAILURE CODE [DBVRKR] 1789
FAILURE CODE [DBVVKR] 1790
FAILURE CODE [DBVWKR] 1791
FAILURE CODE [DD12KA] 1792
FAILURE CODE [DD12KB] 1794
FAILURE CODE [DD13KA] 1796
FAILURE CODE [DD13KB] 1798
FAILURE CODE [DD14KA] 1800
FAILURE CODE [DD14KB] 1802
FAILURE CODE [DDDDKA] 1804
FAILURE CODE [DDDDKB] 1806
FAILURE CODE [DDDDKX] 1808
FAILURE CODE [DDDHKB] 1809
FAILURE CODE [DDDKKA] 1811
FAILURE CODE [DDDKKB] 1813
FAILURE CODE [DDDLKA] 1815
FAILURE CODE [DDDLKB] 1817
FAILURE CODE [DDE2KA] 1819
FAILURE CODE [DDKAKA] 1820
FAILURE CODE [DDKAKB] 1822
FAILURE CODE [DDKBKA] 1824
FAILURE CODE [DDKBKB] 1826
FAILURE CODE [DDKCL4] 1828
FAILURE CODE [DDKEL4] 1830
FAILURE CODE [DDKHKA] 1832
FAILURE CODE [DDKHKB] 1834
FAILURE CODE [DDKQKA] 1836
FAILURE CODE [DDKQKB] 1838
FAILURE CODE [DDKRKA] 1840
FAILURE CODE [DDKRKB] 1842
FAILURE CODE [DDKSKA] 1844
FAILURE CODE [DDKSKB] 1846
FAILURE CODE [DDN7L4] 1848
FAILURE CODE [DDN8L4] 1850
FAILURE CODE [DDNLKA] 1852
FAILURE CODE [DDNLKB] 1854
FAILURE CODE [DDTSL1] 1856
FAILURE CODE [DDTSLH] 1858
FAILURE CODE [DFA4KX] 1860
FAILURE CODE [DFA4KZ] 1861
FAILURE CODE [DFA4L8] 1862
FAILURE CODE [DFA5KA] 1864
FAILURE CODE [DFA5KY] 1866
FAILURE CODE [DFA6KA] 1868
FAILURE CODE [DFA6KY] 1870
FAILURE CODE [DFA7KX] 1872
FAILURE CODE [DFA7KZ] 1873
FAILURE CODE [DFA7L8] 1874
FAILURE CODE [DFA8KA] 1876
FAILURE CODE [DFA8KY] 1878
FAILURE CODE [DFA9KA] 1880
FAILURE CODE [DFA9KY] 1882
FAILURE CODE [DFAAKX] 1884
FAILURE CODE [DFAAKZ] 1885
FAILURE CODE [DFAAL8] 1886
FAILURE CODE [DFABKA] 1888
FAILURE CODE [DFABKY] 1890
FAILURE CODE [DFACKA] 1892
FAILURE CODE [DFACKY] 1894
FAILURE CODE [DGS1KA] 1896
FAILURE CODE [DGS1KX] 1898
FAILURE CODE [DGT1KA] 1900
FAILURE CODE [DGT1KX] 1902
FAILURE CODE [DGT4KA] 1904
FAILURE CODE [DGT4KY] 1906
FAILURE CODE [DH21KA] 1908
FAILURE CODE [DH21KY] 1910
FAILURE CODE [DHA4KA] 1912
FAILURE CODE [DHAAMA] 1914
FAILURE CODE [DHABMA] 1915
FAILURE CODE [DHACMA] 1916
FAILURE CODE [DHADMA] 1917
FAILURE CODE [DHT2L6] 1918
FAILURE CODE [DHT3KX] 1919
FAILURE CODE [DHT5KA] 1920
FAILURE CODE [DHT5KY] 1922
FAILURE CODE [DHT7KA] 1924
FAILURE CODE [DHT7KY] 1926
FAILURE CODE [DK10KA] 1928
FAILURE CODE [DK10KB] 1930
FAILURE CODE [DK30KA] 1932
FAILURE CODE [DK30KX] 1934
FAILURE CODE [DK30KY] 1935
FAILURE CODE [DK30KZ] 1937
FAILURE CODE [DK30L8] 1938
FAILURE CODE [DK31KA] 1940
FAILURE CODE [DK31KY] 1942
FAILURE CODE [DK40KA] 1944
FAILURE CODE [DK40KY] 1946
FAILURE CODE [DK55KX] 1948
FAILURE CODE [DK55KZ] 1949
FAILURE CODE [DK55L8] 1950
FAILURE CODE [DK56KA] 1951
FAILURE CODE [DK56KY] 1953
FAILURE CODE [DK57KA] 1955
FAILURE CODE [DK57KY] 1957
FAILURE CODE [DK60KA] 1959
FAILURE CODE [DK60KY] 1961
FAILURE CODE [DK80KR] 1963
FAILURE CODE [DK80KT] 1966
FAILURE CODE [DKH1KA] 1967
FAILURE CODE [DKH1KY] 1969
FAILURE CODE [DKSGL8] 1971
FAILURE CODE [DKSHKA] 1973
FAILURE CODE [DKSHKB] 1976
FAILURE CODE [DKSJKA] 1978
FAILURE CODE [DKSJKB] 1981
FAILURE CODE [DKSKKA] 1983
FAILURE CODE [DKSKKB] 1986
FAILURE CODE [DKSKMB] 1988
FAILURE CODE [DKSLL8] 1990
FAILURE CODE [DKSMKA] 1992
FAILURE CODE [DKSMKB] 1995
FAILURE CODE [DKSNKA] 1997
FAILURE CODE [DKSNKB] 2000
FAILURE CODE [DKSPKA] 2002
FAILURE CODE [DKSPKB] 2005
FAILURE CODE [DKSPMB] 2007
FAILURE CODE [DLM3KA] 2009
FAILURE CODE [DLM3MB] 2010
FAILURE CODE [DLT3KA] 2011
FAILURE CODE [DLT3KB] 2013
FAILURE CODE [DNDAMC] 2015
FAILURE CODE [DNDBKA] 2017
FAILURE CODE [DNDBKB] 2019
FAILURE CODE [DNDCKA] 2021
FAILURE CODE [DNDCKB] 2023
FAILURE CODE [DNDDKA] 2025
FAILURE CODE [DNDDKB] 2027
FAILURE CODE [DNDEKA] 2029
FAILURE CODE [DNDEKB] 2031
FAILURE CODE [DR21KX] 2033
FAILURE CODE [DR31KX] 2034
FAILURE CODE [DV20KB] 2035
FAILURE CODE [DW7BKA] 2037
FAILURE CODE [DW7BKB] 2039
FAILURE CODE [DWN3KA] 2040
FAILURE CODE [DWN3KB] 2042
FAILURE CODE [DWN3KY] 2044
FAILURE CODE [DWN5KA] 2045
FAILURE CODE [DWN5KB] 2047
FAILURE CODE [DWN5KY] 2049
FAILURE CODE [DWNCKA] 2050
FAILURE CODE [DWNCKB] 2052
FAILURE CODE [DWNCKY] 2053
FAILURE CODE [DWNVKA] 2054
FAILURE CODE [DWNVKB] 2056
FAILURE CODE [DWNWKA] 2058
FAILURE CODE [DWNWKB] 2060
FAILURE CODE [DWNXKA] 2062
FAILURE CODE [DWNXKB] 2064
FAILURE CODE [DWNYKA] 2066
FAILURE CODE [DWNYKB] 2068
FAILURE CODE [DXH1KA] 2070
FAILURE CODE [DXH1KB] 2072
FAILURE CODE [DXH1KY] 2074
FAILURE CODE [DXH4KA] 2075
FAILURE CODE [DXH4KB] 2077
FAILURE CODE [DXH4KY] 2079
FAILURE CODE [DXH5KA] 2080
FAILURE CODE [DXH5KB] 2082
FAILURE CODE [DXH5KY] 2084
FAILURE CODE [DXH6KA] 2085
FAILURE CODE [DXH6KB] 2087
FAILURE CODE [DXH6KY] 2089
FAILURE CODE [DXH7KA] 2090
FAILURE CODE [DXH7KB] 2092
FAILURE CODE [DXH7KY] 2094
FAILURE CODE [DXH8KA] 2095
FAILURE CODE [DXH8KB] 2097
FAILURE CODE [DXH8KY] 2099
FAILURE CODE [DXH9KA] 2100
FAILURE CODE [DXH9KB] 2102
FAILURE CODE [DXH9KY] 2104
FAILURE CODE [DXHAKA] 2105
FAILURE CODE [DXHAKB] 2107
FAILURE CODE [DXHAKY] 2109
FAILURE CODE [DXHBKA] 2110
FAILURE CODE [DXHBKB] 2112
FAILURE CODE [DXHBKY] 2114
FAILURE CODE [DXHCKA] 2115
FAILURE CODE [DXHCKB] 2117
FAILURE CODE [DXHCKY] 2119
FAILURE CODE [DXHRKA] 2120
FAILURE CODE [DXHRKB] 2122
FAILURE CODE [DXHRKY] 2124
FAILURE CODE [DXHSKA] 2125
FAILURE CODE [DXHSKB] 2127
FAILURE CODE [DXHSKY] 2129
FAILURE CODE [DXHTKA] 2130
FAILURE CODE [DXHTKB] 2132
FAILURE CODE [DXHTKY] 2134
FAILURE CODE [DXHUKA] 2135
FAILURE CODE [DXHUKB] 2137
FAILURE CODE [DXHUKY] 2139
FAILURE CODE [DXHWKA] 2140
FAILURE CODE [DXHWKB] 2142
FAILURE CODE [DXHWKY] 2144
FAILURE CODE [DXHXKA] 2145
FAILURE CODE [DXHXKB] 2147
FAILURE CODE [DXHXKY] 2149
FAILURE CODE [DXHYKA] 2150
FAILURE CODE [DXHYKB] 2152
FAILURE CODE [DXHYKY] 2154
FAILURE CODE [DXHZKA] 2155
FAILURE CODE [DXHZKB] 2157
FAILURE CODE [DXHZKY] 2159
FAILURE CODE [DXJ4KA] 2160
FAILURE CODE [DXJ4KB] 2162
FAILURE CODE [DXJ8KA] 2163
FAILURE CODE [DXJ8KB] 2165
FAILURE CODE [DXJ8KY] 2167
FAILURE CODE [DXJ9KA] 2168
FAILURE CODE [DXJ9KB] 2170
FAILURE CODE [DXJ9KY] 2172
FAILURE CODE [DXJBKA] 2173
FAILURE CODE [DXJBKB] 2175
FAILURE CODE [DXJBKY] 2176
FAILURE CODE [DY2HKA] 2177
FAILURE CODE [F7A0KT] 2179
FAILURE CODE [F7A1KK] 2180
FAILURE CODE [F7A8KB] 2183
FAILURE CODE [F7ALKA] 2184
FAILURE CODE [F7ALKB] 2187
FAILURE CODE [F7AQKR] 2189
FAILURE CODE [F7ARKR] 2194
FAILURE CODE [F7ASKA] 2199
FAILURE CODE [F7BSKR] 2203
FAILURE CODE [F7BTKR] 2205
FAILURE CODE [F7C0KR] 2206
FAILURE CODE [F7CRKT] 2210
FAILURE CODE [F9A0KT] 2211
FAILURE CODE [F9A0MC] 2212
FAILURE CODE [F9A1KK] 2213
FAILURE CODE [F9A2KK] 2215
FAILURE CODE [F9AQKR] 2217
FAILURE CODE [F9ARKR] 2222
FAILURE CODE [F9ATKA] 2227
FAILURE CODE [F9ATKB] 2230
FAILURE CODE [F9AUMC] 2232
FAILURE CODE [F@BYNR] 2234
FAILURE CODE [F@BYNS] 2235
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2236
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2236
E-2 ENGINE DOES NOT START IN RADIO CONTROL MODE (ENGINE DOES NOT CRANK) 2240
E-3 ENGINE STOPS DURING OPERATION (SPECIFICATIONS OF RADIO CONTROL) 2243
E-4 MANUAL PREHEATING SYSTEM DOES NOT WORK 2248
E-5 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2251
E-6 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2253
E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2255
E-8 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2259
E-9 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2261
E-10 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2262
E-11 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2264
E-12 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2265
E-13 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2266
E-14 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2267
E-15 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2268
E-16 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2269
E-17 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2271
E-18 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2273
E-19 OPERATION MODE DOES NOT CHANGE 2275
E-20 GEAR SHIFT MODE DOES NOT CHANGE 2276
E-21 MOVEMENT OF MACHINE DOES NOT MATCH TO INSTRUCTIONS IN RADIO CONTROL TRANSMITTER OPERATION 2277
E-22 RADIO CONTROL/ON-BOARD CAN NOT BE CHANGED 2280
E-23 ALL RADIO CONTROL CAN NOT BE OPERATED 2284
E-24 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 2287
E-25 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 2288
E-26 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2289
E-27 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING 2290
E-28 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2291
E-29 SERVICE MODE CANNOT BE SELECTED 2292
E-30 HORN DOES NOT SOUND 2293
E-31 HORN DOES NOT STOP SOUNDING 2295
E-32 HORN DOES NOT SOUND OR DOES NOT STOP SOUNDING (SPECIFICATIONS OF RADIO CONTROL) 2296
E-33 BACKUP ALARM DOES NOT SOUND 2298
E-34 BACKUP ALARM DOES NOT STOP SOUNDING 2299
E-35 HEADLAMP DOES NOT LIGHT UP 2300
E-36 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP 2304
E-37 WORKING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2308
E-38 RED REVOLVING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2311
E-39 BLUE REVOLVING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2314
E-40 GREEN REVOLVING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2317
E-41 ALL WIPERS DO NOT OPERATE 2320
E-42 FRONT WIPER DOES NOT OPERATE 2325
E-43 REAR WIPER DOES NOT OPERATE 2329
E-44 LEFT DOOR WIPER DOES NOT OPERATE 2333
E-45 RIGHT DOOR WIPER DOES NOT OPERATE 2337
E-46 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY 2341
E-47 FAN DOES NOT ROTATE IN REVERSE 2343
E-48 GEAR CANNOT BE SHIFTED 2344
E-49 FRONT WASHER DOES NOT OPERATE 2345
E-50 REAR WASHER DOES NOT OPERATE 2347
E-51 LEFT DOOR WASHER DOES NOT OPERATE 2349
E-52 RIGHT DOOR WASHER DOES NOT OPERATE 2351
E-53 RIPPER PIN PULLER DOES NOT WORK 2353
E-54 KOMTRAX Plus SYSTEM DOES NOT OPERATE NORMALLY 2355
E-55 CANNOT PERFORM DATA DOWNLOAD WIRELESS LAN 2356
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2357
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2357
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) 2358
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) 2361
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 2363
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE 2365
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE 2366
H-6 BRAKE DOES NOT WORK 2368
H-7 POWER TRAIN OIL OVERHEATS 2369
H-8 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 2370
H-9 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT) 2371
H-10 MACHINE CAN TURN (STEERING) ONLY IN ONE DIRECTION 2372
H-11 MACHINE OVERTURNS EXCESSIVELY (STEERING) 2373
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY 2374
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE 2376
H-14 BLADE LIFT SPEED OR POWER IS LOW 2378
H-15 BLADE TILT SPEED OR POWER IS LOW 2380
H-16 RIPPER LIFT SPEED OR POWER IS LOW 2382
H-17 RIPPER TILT SPEED OR POWER IS LOW 2384
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 2386
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 2387
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE 2388
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 2389
H-22 BLADE PITCH CYLINDER DOES NOT OPERATE 2390
H-23 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 2391
H-24 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2392
H-25 SEISMIC ISOLATION OPERATOR SEAT SHAKES ABNORMALLY OR RECEIVES SHOCK 2393
TROUBLESHOOTING OF ENGINE (S-MODE) 2394
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2394
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2395
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2396
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2397
S-4 ENGINE STARTABILITY IS POOR 2398
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2400
S-6 ENGINE STOPS DURING OPERATION 2402
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2404
S-8 ENGINE LACKS POWER 2405
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2407
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2409
S-11 OIL BECOMES CONTAMINATED QUICKLY 2410
S-12 FUEL CONSUMPTION IS EXCESSIVE 2411
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2412
S-14 OIL PRESSURE DROPS 2413
S-15 FUEL MIXES INTO ENGINE OIL 2415
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2416
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2417
S-18 UNUSUAL NOISE IS HEARD 2419
S-19 VIBRATION IS EXCESSIVE 2420
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2421
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2422
S-22 ACTIVE REGENERATION TAKES TIME 2423
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2424
50 DISASSEMBLY AND ASSEMBLY 2425
CONTENTS 2426
ABBREVIATION LIST 2432
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2438
HOW TO READ THIS MANUAL 2438
COATING MATERIALS LIST 2440
SPECIAL TOOLS LIST 2444
SKETCHES OF SPECIAL TOOLS 2454
ENGINE AND COOLING SYSTEM 2480
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2480
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2480
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2488
REMOVE AND INSTALL INJECTOR ASSEMBLY 2499
METHOD FOR REMOVING INJECTOR ASSEMBLY 2500
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2508
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2521
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2521
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2523
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2526
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2527
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2549
REMOVE AND INSTALL COMMON RAIL 2580
METHOD FOR REMOVING COMMON RAIL 2580
METHOD FOR INSTALLING COMMON RAIL 2586
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2593
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2593
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2594
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2595
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2595
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2600
REMOVE AND INSTALL STARTER ASSEMBLY 2605
METHOD FOR REMOVING STARTER ASSEMBLY 2605
METHOD FOR INSTALLING STARTER ASSEMBLY 2606
REMOVE AND INSTALL RADIATOR GUARD ASSEMBLY 2608
METHOD FOR REMOVING RADIATOR GUARD ASSEMBLY 2608
METHOD FOR INSTALLING RADIATOR GUARD ASSEMBLY 2614
REMOVE AND INSTALL COOLING ASSEMBLY 2621
METHOD FOR REMOVING COOLING ASSEMBLY 2621
METHOD FOR INSTALLING COOLING ASSEMBLY 2625
REMOVE AND INSTALL RADIATOR ASSEMBLY 2630
METHOD FOR REMOVING RADIATOR ASSEMBLY 2630
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2632
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2634
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2634
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2636
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2638
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2638
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2640
SWING METHOD RADIATOR FAN DRIVE ASSEMBLY 2642
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2648
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2648
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2652
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2655
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2655
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2657
REMOVE AND INSTALL ENGINE ASSEMBLY 2659
METHOD FOR REMOVING ENGINE ASSEMBLY 2659
METHOD FOR INSTALLING ENGINE ASSEMBLY 2671
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2684
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2684
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2685
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2687
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2687
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2688
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2692
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2692
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2697
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2703
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2703
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2707
REMOVE AND INSTALL KDPF ASSEMBLY 2712
METHOD FOR REMOVING KDPF ASSEMBLY 2712
METHOD FOR INSTALLING KDPF ASSEMBLY 2716
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2721
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2722
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2727
REMOVE AND INSTALL KCCV ASSEMBLY 2734
METHOD FOR REMOVING KCCV ASSEMBLY 2734
METHOD FOR INSTALLING KCCV ASSEMBLY 2736
REMOVE AND INSTALL VGT ASSEMBLY 2739
METHOD FOR REMOVING VGT ASSEMBLY 2739
METHOD FOR INSTALLING VGT ASSEMBLY 2747
REMOVE AND INSTALL AIR CLEANER BRACKET ASSEMBLY 2757
METHOD FOR REMOVING AIR CLEANER BRACKET ASSEMBLY 2757
METHOD FOR INSTALLING AIR CLEANER BRACKET ASSEMBLY 2761
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2767
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2767
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2768
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2769
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2769
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2772
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2775
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2775
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2777
POWER TRAIN 2781
REMOVE AND INSTALL DAMPER ASSEMBLY 2781
METHOD FOR REMOVING DAMPER ASSEMBLY 2781
METHOD FOR INSTALLING DAMPER ASSEMBLY 2789
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY 2799
METHOD FOR DISASSEMBLE DAMPER ASSEMBLY 2799
METHOD FOR ASSEMBLING DAMPER ASSEMBLY 2800
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY 2803
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY 2803
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY 2815
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY 2828
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY 2828
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY 2837
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY 2847
METHOD FOR DISASSEMBLING PTO ASSEMBLY 2847
METHOD FOR ASSEMBLING PTO ASSEMBLY 2850
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2855
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2855
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2859
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2865
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2866
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2878
DISASSEMBLE AND ASSEMBLE STEERING CASE ASSEMBLY 2896
METHOD FOR DISASSEMBLING STEERING CASE ASSEMBLY 2896
METHOD FOR ASSEMBLING STEERING CASE ASSEMBLY 2903
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY 2913
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2913
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY 2914
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY 2915
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2916
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2917
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2922
UNDERCARRIAGE AND FRAME 2932
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2932
METHOD FOR REMOVING TRACK FRAME ASSEMBLY 2932
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY 2936
REMOVE AND INSTALL IDLER ASSEMBLY 2941
METHOD FOR REMOVING IDLER ASSEMBLY 2941
METHOD FOR INSTALLING IDLER ASSEMBLY 2942
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2943
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2943
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2944
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2947
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2947
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2952
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2955
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2955
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2956
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2957
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2957
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2959
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2961
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2961
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2962
REMOVE AND INSTALL NO 1 BOGIE ASSEMBLY 2964
METHOD FOR REMOVING NO 1 BOGIE ASSEMBLY 2965
METHOD FOR INSTALLING NO 1 BOGIE ASSEMBLY 2967
REMOVE AND INSTALL BOGIE ASSEMBLIES 2970
METHOD FOR REMOVING BOGIE ASSEMBLIES 2971
METHOD FOR INSTALLING BOGIE ASSEMBLIES 2974
DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEMBLY 2976
METHOD FOR DIS ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY 2976
METHOD FOR ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY 2977
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2979
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2979
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2979
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2981
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2981
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2982
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2986
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2986
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2987
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2988
METHOD FOR SEPARATING OF TRACK ASSEMBLY 2988
METHOD FOR INSTALLING TRACK ASSEMBLY 2990
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERALLY 2992
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2992
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2994
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD 3008
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 3009
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 3011
DISASSEMBLE AND ASSEMBLE MASTER LINK 3013
METHOD FOR DISASSEMBLING MASTER LINK 3015
METHOD FOR ASSEMBLING MASTER LINK 3015
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 3018
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 3018
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 3023
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS 3028
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS 3028
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS 3029
REMOVE AND INSTALL SEGMENT TEETH 3030
METHOD FOR REMOVING SEGMENT TEETH 3030
METHOD FOR INSTALLING SEGMENT TEETH 3030
REMOVE AND INSTALL POWER LADDER ASSEMBLY 3032
METHOD FOR REMOVING POWER LADDER ASSEMBLY 3032
METHOD FOR INSTALLING POWER LADDER ASSEMBLY 3035
HYDRAULIC SYSTEM 3038
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3038
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3038
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3042
REMOVE AND INSTALL WORK EQUIPMENT PUMP ASSEMBLY 3046
METHOD FOR REMOVING WORK EQUIPMENT PUMP ASSEMBLY 3046
METHOD FOR INSTALLING WORK EQUIPMENT PUMP ASSEMBLY 3050
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 3055
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 3055
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 3055
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY 3057
METHOD FOR REMOVING COOLING FAN PUMP ASSEMBLY 3057
METHOD FOR INSTALLING COOLING FAN PUMP ASSEMBLY 3058
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY 3060
METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY 3060
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY 3060
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 3062
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 3062
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3065
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 3065
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 3071
WORK EQUIPMENT 3078
REMOVE AND INSTALL BLADE ASSEMBLY 3078
METHOD FOR REMOVING BLADE ASSEMBLY 3078
METHOD FOR INSTALLING BLADE ASSEMBLY 3081
DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY 3085
METHOD FOR DISASSEMBLING BLADE ASSEMBLY 3085
METHOD FOR ASSEMBLING BLADE ASSEMBLY 3088
DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY 3092
METHOD FOR DISASSEMBLING GIANT RIPPER ASSEMBLY 3092
METHOD FOR ASSEMBLING GIANT RIPPER ASSEMBLY 3094
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3097
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3097
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3100
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3103
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3104
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3110
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT CYLINDER ASSEMBLY 3120
METHOD FOR DISASSEMBLING BLADE TILT CYLINDER ASSEMBLY 3120
METHOD FOR ASSEMBLING BLADE TILT CYLINDER ASSEMBLY 3122
DISASSEMBLE AND ASSEMBLE RIPPER PIN PULLER CYLINDER ASSEMBLY 3125
METHOD FOR DISASSEMBLYING RIPPER PIN PULLER CYLINDER ASSEMBLY 3125
METHOD FOR ASSEMBLYING RIPPER PIN PULLER CYLINDER ASSEMBLY 3126
CAB AND ITS ATTACHMENTS 3128
REMOVE AND INSTALL ROPS GUARD 3128
METHOD FOR REMOVING ROPS GUARD 3128
METHOD FOR INSTALLING ROPS GUARD 3128
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3129
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3129
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3133
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3137
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 3138
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 3138
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3142
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3142
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3148
REMOVE AND INSTALL OPERATOR’S SEAT 3154
METHOD FOR REMOVING OPERATOR’S SEAT 3154
METHOD FOR INSTALLING OPERATOR’S SEAT 3155
REMOVE AND INSTALL SEAT BELT 3157
METHOD FOR REMOVING SEAT BELT 3157
METHOD FOR INSTALLING SEAT BELT 3158
ELECTRICAL SYSTEM 3159
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3159
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3159
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3163
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY 3168
METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY 3168
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY 3169
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3170
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3170
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3171
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3172
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3172
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3173
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3175
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3175
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3176
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3178
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3178
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3179
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3180
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3180
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3180
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY 3182
METHOD FOR REMOVING KOMTRAX Plus CONTROLLER ASSEMBLY 3182
METHOD FOR INSTALLING KOMTRAX Plus CONTROLLER ASSEMBLY 3183
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 3185
METHOD FOR REMOVING WIRELESS LAN UNIT ASSEMBLY 3185
METHOD FOR NSTALLING WIRELESS LAN UNIT ASSEMBLY 3186
REMOVE AND INSTALL CONTROL BOX 3188
METHOD FOR REMOVING CONTROL BOX 3188
METHOD FOR INSTALLING CONTROL BOX 3189
REMOVE AND INSTALL OPTIONAL CONTROLLER ASSEMBLY 3190
METHOD FOR REMOVING OPTIONAL CONTROLLER ASSEMBLY 3190
METHOD FOR INSTALLING OPTIONAL CONTROLLER ASSEMBLY 3193
REMOVE AND INSTALL NAVIGATION CONTROLLER ASSEMBLY 3197
METHOD FOR REMOVING NAVIGATION CONTROLLER ASSEMBLY 3197
METHOD FOR INSTALLING NAVIGATION CONTROLLER ASSEMBLY 3198
REMOVE AND INSTALL AUX BOX 3200
METHOD FOR REMOVING AUX BOX 3200
METHOD FOR INSTALLING AUX BOX 3202
REMOVE AND INSTALL IMU SENSOR 3204
METHOD FOR REMOVING IMU SENSOR 3204
METHOD FOR INSTALLING IMU SENSOR 3205
REMOVE AND INSTALL RADIO CONTROL RECEIVER 3207
METHOD FOR REMOVING RADIO CONTROL RECEIVER 3207
METHOD FOR INSTALLING RADIO CONTROL RECEIVER 3208
60 MAINTENANCE STANDARD 3211
CONTENTS 3212
ABBREVIATION LIST 3214
ENGINE AND COOLING SYSTEM 3220
MAINTENANCE STANDARD OF ENGINE MOUNT 3220
MAINTENANCE STANDARD OF DAMPER 3222
MAINTENANCE STANDARD OF COOLING SYSTEM 3224
MAINTENANCE STANDARD OF COOLING FAN PUMP 3226
MAINTENANCE STANDARD OF SERVO VALVE 3234
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3236
POWER TRAIN 3239
MAINTENANCE STANDARD OF UNIVERSAL JOINT 3239
MAINTENANCE STANDARD OF POWER TRAIN MOUNT 3240
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 3242
MAINTENANCE STANDARD OF TORQUE CONVERTER CONTROL VALVE 3247
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3249
MAINTENANCE STANDARD OF STATOR CLUTCH ECMV 3250
MAINTENANCE STANDARD OF TRANSMISSION 3251
MAINTENANCE STANDARD OF PTO, TRANSMISSION LUBRICATION PUMP, AND POWER TRAIN PUMP 3257
MAINTENANCE STANDARD OF TRANSMISSION ECMV 3259
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3260
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE 3261
MAINTENANCE STANDARD OF TRANSFER, BEVEL GEAR SHAFT, AND STEERING 3262
MAINTENANCE STANDARD OF BRAKE SOLENOID VALVE 3268
MAINTENANCE STANDARD OF SUDDEN STOP PREVENTION VALVE 3269
MAINTENANCE STANDARD OF FINAL DRIVE 3270
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 3274
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 3275
UNDERCARRIAGE AND FRAME 3277
MAINTENANCE STANDARD OF MAIN FRAME 3277
MAINTENANCE STANDARD OF SUSPENSION 3279
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 3282
MAINTENANCE STANDARD OF IDLER 3286
MAINTENANCE STANDARD OF TRACK ROLLER BOGIE 3288
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES 3289
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE 3292
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 3293
MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE 3295
HYDRAULIC SYSTEM 3296
MAINTENANCE STANDARD OF HYDRAULIC TANK 3296
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3297
MAINTENANCE STANDARD OF SCAVENGING PUMP 3300
MAINTENANCE STANDARD OF CONTROL VALVE 3301
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE 3311
MAINTENANCE STANDARD OF QUICK DROP VALVE 3314
WORK EQUIPMENT 3315
MAINTENANCE STANDARD OF CYLINDER STAY 3315
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 3316
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 3322
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER 3323
MAINTENANCE STANDARD OF PIN PULLER CYLINDER 3324
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 3325
MAINTENANCE STANDARD OF VARIABLE MULTI-SHANK RIPPER 3327
MAINTENANCE STANDARD OF VARIABLE GIANT RIPPER 3329
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 3331
MAINTENANCE STANDARD OF RIPPER TILT CYLINDER 3332
CAB AND ITS ATTACHMENTS 3333
MAINTENANCE STANDARD OF CAB MOUNT 3333
MAINTENANCE STANDARD OF ROPS 3334
80 APPENDIX 3335
CONTENTS 3336
ABBREVIATION LIST 3338
AIR CONDITIONER SYSTEM 3344
PRECAUTIONS FOR REFRIGERANT 3344
AIR CONDITIONER COMPONENT 3345
SPECIFICATIONS OF AIR CONDITIONER 3347
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3348
OUTLINE OF REFRIGERATION CYCLE 3349
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3351
AIR CONDITIONER UNIT 3351
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3351
FUNCTION OF AIR CONDITIONER UNIT 3353
COMPONENT PARTS OF AIR CONDITIONER UNIT 3355
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3356
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3356
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3356
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3356
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3357
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3357
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3357
FUNCTION OF TRIPLE PRESSURE SWITCH 3358
AIR CONDITIONER CONTROLLER 3359
STRUCTURE OF AIR CONDITIONER CONTROLLER 3359
COMPRESSOR 3360
STRUCTURE OF COMPRESSOR 3360
SPECIFICATIONS OF COMPRESSOR 3360
FUNCTION OF COMPRESSOR 3360
CONDENSER 3361
STRUCTURE OF CONDENSER 3361
SPECIFICATIONS OF CONDENSER 3361
FUNCTION OF CONDENSER 3361
RECEIVER DRIER 3362
STRUCTURE OF RECEIVER DRIER 3362
SPECIFICATIONS OF RECEIVER DRIER 3362
FUNCTION OF RECEIVER DRIER 3362
SENSORS FOR AIR CONDITIONER SYSTEM 3363
STRUCTURE OF SUNLIGHT SENSOR 3363
FUNCTION OF SUNLIGHT SENSOR 3363
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3363
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3363
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3365
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3367
AIR CONDITIONER SYSTEM DIAGRAM 3369
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3370
FUNCTION OF AIR CONDITIONER CONTROLLER 3371
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3372
TESTING AIR LEAKAGE (DUCT) 3381
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3381
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3384
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3385
TEST VENT (MODE) CHANGEOVER 3386
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3386
TESTING FRESH/RECIRC AIR CHANGEOVER 3387
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3387
TEST SUNLIGHT SENSOR 3388
METHOD FOR TESTING SUNLIGHT SENSOR 3388
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 3389
METHOD FOR TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 3389
TEST RELAYS 3390
METHOD FOR TESTING RELAYS 3390
AIR CONDITIONER TROUBLESHOOTING CHART 1 3391
AIR CONDITIONER TROUBLESHOOTING CHART 2 3392
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3395
FAILURE CODE [879AKA] 3397
FAILURE CODE [879AKB] 3398
FAILURE CODE [879BKA] 3399
FAILURE CODE [879BKB] 3401
FAILURE CODE [879CKA] 3403
FAILURE CODE [879CKB] 3404
FAILURE CODE [879DKZ] 3405
FAILURE CODE [879EMC] 3407
FAILURE CODE [879FMC] 3408
FAILURE CODE [879GKX] 3409
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3411
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3413
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3417
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3419
TROUBLESHOOTING USING GAUGE PRESSURE 3421
CONNECTION OF SERVICE TOOL 3424
METHOD FOR CONNECTING SERVICE TOOL 3424
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3426
HANDLE COMPRESSOR OIL 3428
90 CIRCUIT DIAGRAMS 3431
CONTENTS 3432
ABBREVIATION LIST 3433
HYDRAULIC CIRCUIT DIAGRAM 3439
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3439
HYDRAULIC CIRCUIT DIAGRAM 3443
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3444
ELECTRICAL CIRCUIT DIAGRAM 3445
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3445
ELECTRICAL CIRCUIT DIAGRAM (1/12) 3449
ELECTRICAL CIRCUIT DIAGRAM (2/12) 3450
ELECTRICAL CIRCUIT DIAGRAM (3/12) 3451
ELECTRICAL CIRCUIT DIAGRAM (4/12) 3452
ELECTRICAL CIRCUIT DIAGRAM (5/12) 3453
ELECTRICAL CIRCUIT DIAGRAM (6/12) 3454
ELECTRICAL CIRCUIT DIAGRAM (7/12) 3455
ELECTRICAL CIRCUIT DIAGRAM (8/12) 3456
ELECTRICAL CIRCUIT DIAGRAM (9/12) 3457
ELECTRICAL CIRCUIT DIAGRAM (10/12) 3458
ELECTRICAL CIRCUIT DIAGRAM (11/12) 3459
ELECTRICAL CIRCUIT DIAGRAM (12/12) 3460
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(1/14) 3461
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(2/14) 3462
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(3/14) 3463
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(4/14) 3464
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(5/14) 3465
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(6/14) 3466
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(7/14) 3467
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(8/14) 3468
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(9/14) 3469
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(10/14) 3470
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(11/14) 3471
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(12/14) 3472
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(13/14) 3473
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM(14/14) 3474
INDEX 3475

DESCRIPTION:

Komatsu D375Ai Bulldozer Shop Manual SEN06653-01 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 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.

S.V 29/12/24