Komatsu D61EXi-24,D61PXi-24 Bulldozer Shop Manual KEBM657808 PDF

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Komatsu D61EXi-24,D61PXi-24 Bulldozer Shop Manual KEBM657808  – PDF DOWNLOAD

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Komatsu D61EXi-24,D61PXi-24 Bulldozer Shop Manual KEBM657808  – PDF DOWNLOAD

Language : English
Pages : 3189
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D61EXi-24,D61PXi-24 Bulldozer Shop Manual KEBM657808  – PDF DOWNLOAD

SERIAL NUMBERS

• D61EXi-B60001  and up
• D61PXi-B60001 and up

COVER 0
00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 24
FOREWORD, SAFETY, BASIC INFORMATION . 30
HOW TO READ THE SHOP MANUAL . 30
SAFETY NOTICE FOR OPERATION . 32
PRECAUTIONS TO PREVENT FIRE . 40
ACTIONS IF FIRE OCCURS 42
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 43
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 44
PRECAUTIONS FOR DEF . 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 . 45
STORE AdBlue/DEF 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 50
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 57
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 59
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 60
PRACTICAL USE OF KOMTRAX 61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 64
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 66
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 70
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 76
HOW TO READ ELECTRICAL WIRE CODE 77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 81
STANDARD TIGHTENING TORQUE TABLE 84
CONVERSION TABLE 91
01 SPECIFICATIONS . 97
CONTENTS 98
ABBREVIATION LIST . 99
SPECIFICATIONS 105
SPECIFICATION DRAWING . 105
SPECIFICATION DRAWING: D61EXI-24 105
SPECIFICATION DRAWING: D61PXI-24 107
SPECIFICATIONS 109
SPECIFICATIONS: D61EXI-24 . 109
SPECIFICATIONS: D61PXI-24 . 115
WEIGHT TABLE 120
WEIGHT TABLE: D61EXI-24 . 120
WEIGHT TABLE: D61PXI-24 . 122
TABLE OF FUEL, COOLANT, AND LUBRICANTS 124
10 STRUCTURE AND FUNCTION . 125
CONTENTS 126
ABBREVIATION LIST . 130
UREA SCR SYSTEM . 136
LAYOUT DRAWING OF UREA SCR SYSTEM . 136
UREA SCR SYSTEM DIAGRAM . 139
FUNCTION OF UREA SCR SYSTEM . 140
FUNCTION OF AdBlue/DEF SYSTEM . 140
INDUCEMENT STRATEGY . 142
COMPONENT PARTS OF UREA SCR SYSTEM 156
AdBlue/DEF MIXING TUBE 156
SCR ASSEMBLY 157
AdBlue/DEF TANK . 159
AdBlue/DEF PUMP . 161
AdBlue/DEF INJECTOR . 162
AdBlue/DEF HOSE . 163
AdBlue/DEF TANK HEATING VALVE . 164
BOOT-UP SYSTEM 165
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 165
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 166
SYSTEM OPERATING LAMP SYSTEM 167
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 167
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 167
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 167
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 168
BATTERY DISCONNECT SWITCH . 170
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH . 170
FUNCTION OF BATTERY DISCONNECT SWITCH . 170
ENGINE SYSTEM . 172
LAYOUT DRAWING OF ENGINE SYSTEM . 172
ENGINE CONTROL SYSTEM . 174
LAYOUT OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 174
LAYOUT OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 176
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 178
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 180
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 182
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 184
AUTOMATIC IDLE STOP SYSTEM 186
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 186
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 187
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 187
COMPONENT PARTS OF ENGINE SYSTEM 190
DAMPER 190
VGT . 191
EGR SYSTEM 195
EGR VALVE . 197
EGR COOLER 199
KCCV SYSTEM . 201
KCCV VENTILATOR . 203
KDPF 205
COOLING SYSTEM 209
LAYOUT DRAWING OF COOLING SYSTEM 209
SPECIFICATIONS OF COOLING SYSTEM 210
COOLING FAN CONTROL SYSTEM 211
COOLING FAN CONTROL SYSTEM DIAGRAM 211
FUNCTION OF COOLING FAN CONTROL SYSTEM 212
COMPONENT PARTS OF COOLING SYSTEM . 214
COOLING FAN MOTOR . 214
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE . 219
HYDRAULIC OIL COOLER BYPASS VALVE . 221
HST CHARGE SAFETY VALVE . 222
CONTROL SYSTEM 224
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 224
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 225
MACHINE MONITOR SYSTEM 226
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 226
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 227
FUNCTION OF MACHINE MONITOR SYSTEM 227
KOMTRAX SYSTEM 228
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 228
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 228
FUNCTION OF KOMTRAX SYSTEM 229
COMPONENT PARTS OF CONTROL SYSTEM . 230
MACHINE MONITOR . 230
KOMTRAX TERMINAL 245
GATEWAY FUNCTION CONTROLLER . 247
COMMUNICATION TERMINAL 250
HST CONTROLLER 252
ENGINE CONTROLLER . 256
FUEL CONTROL DIAL . 262
DECELERATOR AND BRAKE POTENTIOMETER . 264
HYDRAULIC SYSTEM 266
LAYOUT DRAWING OF HYDRAULIC SYSTEM 266
CLSS 267
STRUCTURE OF CLSS . 267
FUNCTION OF CLSS 268
COMPONENT PARTS OF HYDRAULIC SYSTEM . 270
HYDRAULIC TANK 270
WORK EQUIPMENT AND COOLING FAN PUMP . 272
LS VALVE 280
PC VALVE 281
CONTROL VALVE . 284
POWER TRAIN SYSTEM 305
LAYOUT DRAWING OF HST SYSTEM 305
OPERATION OF HST SYSTEM . 306
STEERING AND BRAKE CONTROL SYSTEM . 308
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM . 308
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM . 308
HST CONTROL SYSTEM 310
HST CONTROL SYSTEM DIAGRAM 310
GEAR SHIFT CONTROL FUNCTION . 311
ENGINE LOW SPEED MATCHING CONTROL FUNCTION 315
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION 315
DECELERATION AND BRAKE CONTROL FUNCTION . 317
GEAR SHIFT CONTROL FUNCTION BY LOAD . 318
TURN CONTROL FUNCTION . 318
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION . 319
PARKING BRAKE CONTROL SYSTEM 321
PARKING BRAKE CONTROL SYSTEM DIAGRAM 321
FUNCTION OF PARKING BRAKE CONTROL SYSTEM 322
OPERATION OF PARKING BRAKE CONTROL SYSTEM . 323
COMPONENT PARTS OF POWER TRAIN SYSTEM . 324
HST PUMP 324
HST CHARGE PUMP . 340
HST MOTOR . 341
FINAL DRIVE . 353
ELECTRIC STEERING CONTROL LEVER . 357
WORK EQUIPMENT SYSTEM . 360
WORK EQUIPMENT CONTROL 360
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM . 360
FUNCTION OF WORK EQUIPMENT CONTROL 361
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 363
LAYOUT OF FIXED MULTI-SHANK RIPPER 364
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 365
RIPPER PPC VALVE 365
5-PORT VALVE OF EPC AND SOLENOID 369
PILOT CIRCUIT ACCUMULATOR . 375
ANGLE CONTROL EPC VALVE . 376
QUICK DROP VALVE 379
PISTON VALVE 381
ELECTRIC BLADE CONTROL LEVER 382
ICT SYSTEM 384
LAYOUT DRAWING OF ICT SYSTEM 384
ICT CONTROL SYSTEM DIAGRAM 386
BLADE CONTROL SYSTEM 388
FUNCTION OF BLADE CONTROL SYSTEM 388
LEVELING MODE SYSTEM DIAGRAM 390
FUNCTION OF LEVELING MODE . 391
OPERATION OF LEVELING MODE 391
DOZING MODE SYSTEM DIAGRAM 392
FUNCTION OF DOZING MODE . 392
OPERATION OF DOZING MODE 392
SMOOTH START SYSTEM . 394
SMOOTH START SYSTEM DIAGRAM . 394
FUNCTION OF SMOOTH START SYSTEM . 394
OPERATION OF SMOOTH START SYSTEM 394
SLIP CONTROL SYSTEM . 396
SLIP CONTROL SYSTEM DIAGRAM . 396
FUNCTION OF SLIP CONTROL SYSTEM . 396
OPERATION OF SLIP CONTROL SYSTEM 396
ASSIST CONTROL SYSTEM . 397
ASSIST CONTROL SYSTEM DIAGRAM . 397
FUNCTION OF ASSIST CONTROL SYSTEM . 397
OPERATION OF ASSIST CONTROL SYSTEM 398
HST SPEED RANGE CONTROL SYSTEM 399
HST SPEED RANGE CONTROL SYSTEM DIAGRAM 399
FUNCTION OF HST SPEED RANGE CONTROL SYSTEM 399
OPERATION OF HST SPEED RANGE CONTROL SYSTEM . 399
COMPONENT PARTS OF ICT SYSTEM . 401
ICT SENSOR CONTROLLER . 401
CONTROL BOX . 405
GNSS RECEIVER . 408
GNSS ANTENNA 412
IMU SENSOR 413
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER . 417
STROKE SENSOR FOR BLADE TILT CYLINDER . 420
STROKE SENSOR FOR BLADE ANGLE CYLINDER 422
UNDERCARRIAGE AND FRAME . 424
MAIN FRAME 424
STRUCTURE OF MAIN FRAME . 424
SUSPENSION 425
STRUCTURE OF SUSPENSION . 425
SPECIFICATIONS OF SUSPENSION 426
FUNCTION OF SUSPENSION 427
TRACK FRAME AND IDLER CUSHION . 428
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 428
FUNCTION OF TRACK FRAME AND IDLER CUSHION . 429
WORK EQUIPMENT 431
STRUCTURE OF FRONT WORK EQUIPMENT . 431
STRUCTURE OF FIXED MULTI-SHANK RIPPER . 432
CAB AND ITS ATTACHMENTS . 433
ROPS CAB 433
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) . 433
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 434
FUNCTION OF ROPS CAB 435
CAB MOUNT . 436
STRUCTURE OF CAB MOUNT 436
FUNCTION OF CAB MOUNT . 436
20 STANDARD VALUE TABLE . 437
CONTENTS 438
ABBREVIATION LIST . 439
STANDARD VALUE TABLE FOR ENGINE . 445
STANDARD VALUE TABLE FOR ENGINE: D61EXI-24 445
STANDARD VALUE TABLE FOR ENGINE: D61PXI-24 449
STANDARD VALUE TABLE FOR MACHINE 453
STANDARD VALUE TABLE FOR MACHINE: D61EXI-24 . 453
STANDARD VALUE TABLE FOR MACHINE: D61PXI-24 . 470
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 487
30 TESTING AND ADJUSTING 489
CONTENTS 490
ABBREVIATION LIST . 494
RELATED INFORMATION ON TESTING AND ADJUSTING 500
TOOLS FOR TESTING AND ADJUSTING . 500
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 508
ENGINE AND COOLING SYSTEM . 513
TEST ENGINE SPEED . 513
METHOD FOR TESTING ENGINE SPEED . 513
TEST BOOST PRESSURE . 516
METHOD FOR TESTING BOOST PRESSURE . 516
TEST EXHAUST GAS COLOR 518
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 518
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 520
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 522
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 522
TEST AND ADJUST VALVE CLEARANCE . 524
METHOD FOR TESTING VALVE CLEARANCE 524
METHOD FOR ADJUSTING VALVE CLEARANCE 525
TEST COMPRESSION PRESSURE . 526
METHOD FOR TESTING COMPRESSION PRESSURE . 526
TEST BLOWBY PRESSURE 531
METHOD FOR TESTING BLOWBY PRESSURE 531
TEST ENGINE OIL PRESSURE 534
METHOD FOR TESTING ENGINE OIL PRESSURE 534
TEST EGR VALVE AND VGT OIL PRESSURE . 535
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 535
TEST FUEL PRESSURE 537
METHOD FOR TESTING FUEL PRESSURE 538
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 543
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 544
BLEEDING AIR FROM FUEL SYSTEM . 550
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 550
TEST FUEL CIRCUIT FOR LEAKAGE . 551
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 551
HANDLE CYLINDER CUT-OUT MODE OPERATION 553
HANDLE NO-INJECTION CRANKING OPERATION 554
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 555
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE . 555
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 556
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 556
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS . 557
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS . 557
TEST ALTERNATOR BELT 558
METHOD FOR REMOVING ALTERNATOR BELT . 558
TEST AUTOMATIC TENSIONER 560
METHOD FOR TESTING AUTOMATIC TENSIONER 560
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 562
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 562
TEST SCR RELATED FUNCTIONS 563
TEST AdBlue/DEF PUMP RAISED PRESSURE 567
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 570
TEST AdBlue/DEF LINE HEATER RELAY 1 . 575
TEST AdBlue/DEF LINE HEATER RELAY 2 . 578
TEST AdBlue/DEF PUMP HEATER RELAY . 581
TEST AdBlue/DEF TANK HEATER VALVE . 585
TEST DENITRATION EFFICIENCY OF SCR 589
CLEAN AdBlue/DEF TANK . 592
METHOD FOR CLEANING AdBlue/DEF TANK . 592
CLEAN AdBlue/DEF TANK MOUNTING PORTION 596
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 596
CLEAN AdBlue/DEF PUMP . 597
CLEAN AdBlue/DEF PUMP . 597
POWER TRAIN . 603
TEST AND ADJUST HST OIL PRESSURE 603
METHOD FOR TESTING HST OIL PRESSURE . 603
METHOD FOR ADJUSTING HST OIL PRESSURE . 606
BLEED AIR FROM HST PUMP . 608
METHOD FOR BLEEDING AIR FROM HST PUMP . 608
TEST OUTLET PRESSURE OF SOLENOID VALVE 609
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 609
TEST TRAVEL DEVIATION . 614
METHOD FOR TESTING TRAVEL DEVIATION . 614
TEST BRAKE PERFORMANCE SIMPLY . 616
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY . 616
TEST AND ADJUST DECELERATION/BRAKE PEDAL 617
METHOD FOR TESTING DECELERATION/BRAKE PEDAL . 617
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL . 619
ADJUST PARKING BRAKE LEVER 621
METHOD FOR ADJUSTING PARKING BRAKE LEVER 621
MOVE MACHINE WHEN IT CANNOT TRAVEL 623
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 623
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT 625
UNDERCARRIAGE AND FRAME . 627
CHECK AND ADJUST IDLER CLEARANCE 627
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE . 627
TESTING SPROCKET WEAR . 628
METHOD FOR TESTING SPROCKET WEAR 628
TEST AND ADJUST TRACK TENSION . 629
METHOD FOR TESTING TRACK TENSION 629
METHOD FOR ADJUSTING TRACK TENSION 629
HYDRAULIC SYSTEM 631
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 631
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 631
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 632
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES . 632
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES . 633
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT . 635
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 635
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 636
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 637
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE 637
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 639
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 639
TEST COOLING FAN SPEED 640
METHOD FOR TESTING COOLING FAN SPEED 640
TEST COOLING FAN CIRCUIT OIL PRESSURE . 641
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE . 641
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 643
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER . 643
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER . 643
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 644
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 645
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 645
BLEED AIR FROM WORK EQUIPMENT CYLINDERS . 648
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS . 648
WORK EQUIPMENT 649
ADJUST WORK EQUIPMENT LOCK LEVER 649
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 649
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER 651
TEST PLAY OF BLADE ELECTRIC LEVER . 653
ADJUST PLAY OF BLADE ELECTRIC LEVER . 653
REPLACE UNIVERSAL JOINT . 654
ELECTRICAL SYSTEM . 661
SET AND OPERATE MACHINE MONITOR . 661
OPERATOR MODE . 665
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 665
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 665
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 666
CHECKING FUNCTION OF SERVICE METER 666
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD . 666
SERVICE MODE 669
METHOD FOR OPERATING SERVICE MODE . 669
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 671
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 677
ABNORMALITY RECORD MENU . 689
METHOD FOR CONFIRMING MAINTENANCE RECORD 693
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 694
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 698
DEFAULT MENU 700
DIAGNOSTIC TESTS MENU . 707
ADJUSTMENT MENU . 716
METHOD FOR PERFORMING NO-INJECTION CRANKING . 784
KOMTRAX SETTINGS MENU . 787
METHOD FOR DISPLAYING SERVICE MESSAGE . 791
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) . 793
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 798
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 800
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 806
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 808
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED . 808
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 814
ADJUST REARVIEW CAMERA ANGLE 816
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 816
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 817
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 818
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 819
TEST DIODES . 820
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 820
METHOD FOR TESTING DIODE USING ANALOG TESTER 820
ICT SYSTEM 821
SET AND OPERATE CONTROL BOX . 821
TEST AND ADJUST ICT RELATED DEVICES . 822
CALIBRATE BLADE EDGE POSITION . 825
METHOD FOR OPERATING BLADE CALIBRATION MENU (PITCH ROD CALIBRATION) . 826
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A) 829
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B) 834
CALIBRATE IMU SENSOR 848
METHOD FOR CALIBRATING IMU SENSOR . 848
RESET CYLINDER STROKE END . 855
RESET LIFT CYLINDER STROKE END 855
RESET TILT CYLINDER STROKE END 856
RESET ANGLE CYLINDER STROKE END . 856
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE . 858
CHECK BLADE ELEVATION, ADJUST . 859
CHECK BLADE ELEVATION (FOR OLD CONTROL BOX) . 859
CHECK BLADE ELEVATION (FOR NEW CONTROL BOX) . 861
ADJUST BLADE ELEVATION (FOR OLD CONTROL BOX) 864
ADJUST BLADE ELEVATION (FOR NEW CONTROL BOX) 865
TEST STROKE SENSOR FOR LIFT CYLINDER 867
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER 867
TEST STROKE SENSOR FOR TILT CYLINDER 869
METHOD FOR TESTING STROKE SENSOR FOR TILT CYLINDER 869
TEST STROKE SENSOR FOR ANGLE CYLINDER . 871
METHOD FOR TESTING STROKE SENSOR FOR ANGLE CYLINDER . 871
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER 873
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER . 873
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER . 874
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED . 875
METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED . 875
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED 878
Pm CLINIC . 881
Pm CLINIC SERVICE . 881
Pm CLINIC CHECK SHEET: D61EXI-24 883
Pm CLINIC CHECK SHEET: D61PXI-24 890
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61EXI-24 897
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D61PXI-24 900
40 TROUBLESHOOTING 903
CONTENTS 904
ABBREVIATION LIST . 916
RELATED INFORMATION ON TROUBLESHOOTING 922
GENERAL TROUBLESHOOTING POINTS 922
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 923
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 938
CHECKS BEFORE TROUBLESHOOTING . 940
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 942
WALK-AROUND CHECK . 942
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 944
CHECK FUEL LEVEL AND TYPE . 944
CHECK IMPURE INGREDIENT IN FUEL . 944
CHECK AdBule/DEF LEVEL AND TYPE . 945
CHECK FUEL PREFILTER 945
CHECK MAIN FILTER . 947
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE . 948
CHECK COOLANT LEVEL (RESERVOIR TANK) 949
CHECK CLOGGING OF AIR CLEANER . 950
CLEAN OUTER ELEMENT . 950
REPLACE ELEMENT . 953
CHECK HYDRAULIC OIL LEVEL . 953
CHECK HYDRAULIC OIL STRAINER 954
CHECK HYDRAULIC FILTER 957
CHECK OIL LEVEL IN FINAL DRIVE CASE . 958
BLEED AIR FROM FUEL SYSTEM 959
BLEED AIR FROM HYDRAULIC SYSTEM . 959
METHOD FOR CHECKING ELECTRIC EQUIPMENT 959
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM . 966
PROCEDURE FOR TROUBLESHOOTING . 973
SYMPTOM AND TROUBLESHOOTING NUMBERS . 976
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 981
CONNECTORS LIST AND LAYOUT (MACHINE WITH KOMTRAX TERMINAL) 983
CONNECTORS LIST AND LAYOUT (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 999
CONNECTOR CONTACT IDENTIFICATION 1015
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .1055
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) .1061
FUSE LOCATION TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1065
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) .1069
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) .1073
FAILURE CODES TABLE .1075
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1096
FAILURE CODE [6091NX] .1096
FAILURE CODE [989L00] .1098
FAILURE CODE [989M00] .1099
FAILURE CODE [989N00] .1100
FAILURE CODE [A1U0N3] .1101
FAILURE CODE [A1U0N4] .1103
FAILURE CODE [A900FR] .1105
FAILURE CODE [A900N6] .1106
FAILURE CODE [A900NY] .1107
FAILURE CODE [AA10NX] .1108
FAILURE CODE [AB00KE] .1110
FAILURE CODE [AQ10N3] .1112
FAILURE CODE [AS00N3] .1114
FAILURE CODE [AS00R2] .1116
FAILURE CODE [AS00R3] .1117
FAILURE CODE [AS00R4] .1118
FAILURE CODE [AS00R5] .1119
FAILURE CODE [AS00R6] .1120
FAILURE CODE [AS00ZK] .1121
FAILURE CODE [AS10KM] .1122
FAILURE CODE [AS10NR] .1123
FAILURE CODE [AS10NT] .1124
FAILURE CODE [B@BAZG] .1125
FAILURE CODE [B@BCNS] .1126
FAILURE CODE [B@CRNS] .1127
FAILURE CODE [B@CRZG] .1128
FAILURE CODE [CA115] 1129
FAILURE CODE [CA122] 1130
FAILURE CODE [CA123] 1132
FAILURE CODE [CA131] 1134
FAILURE CODE [CA132] 1136
FAILURE CODE [CA144] 1138
FAILURE CODE [CA145] 1140
FAILURE CODE [CA153] 1142
FAILURE CODE [CA154] 1145
FAILURE CODE [CA187] 1147
FAILURE CODE [CA221] 1149
FAILURE CODE [CA222] 1151
FAILURE CODE [CA227] 1153
FAILURE CODE [CA234] 1154
FAILURE CODE [CA238] 1155
FAILURE CODE [CA239] 1157
FAILURE CODE [CA249] 1159
FAILURE CODE [CA256] 1161
FAILURE CODE [CA271] 1163
FAILURE CODE [CA272] 1165
FAILURE CODE [CA322] 1167
FAILURE CODE [CA323] 1169
FAILURE CODE [CA324] 1171
FAILURE CODE [CA325] 1173
FAILURE CODE [CA331] 1175
FAILURE CODE [CA332] 1177
FAILURE CODE [CA343] 1179
FAILURE CODE [CA351] 1180
FAILURE CODE [CA352] 1181
FAILURE CODE [CA356] 1184
FAILURE CODE [CA357] 1186
FAILURE CODE [CA386] 1189
FAILURE CODE [CA428] 1190
FAILURE CODE [CA429] 1192
FAILURE CODE [CA435] 1194
FAILURE CODE [CA441] 1196
FAILURE CODE [CA442] 1198
FAILURE CODE [CA449] 1199
FAILURE CODE [CA451] 1200
FAILURE CODE [CA452] 1202
FAILURE CODE [CA488] 1204
FAILURE CODE [CA515] 1205
FAILURE CODE [CA516] 1207
FAILURE CODE [CA553] 1209
FAILURE CODE [CA555] 1210
FAILURE CODE [CA556] 1211
FAILURE CODE [CA559] 1212
FAILURE CODE [CA595] 1215
FAILURE CODE [CA687] 1216
FAILURE CODE [CA689] 1218
FAILURE CODE [CA691] 1221
FAILURE CODE [CA692] 1223
FAILURE CODE [CA697] 1225
FAILURE CODE [CA698] 1226
FAILURE CODE [CA731] 1227
FAILURE CODE [CA778] 1229
FAILURE CODE [CA1117] .1234
FAILURE CODE [CA1664] .1235
FAILURE CODE [CA1669] .1238
FAILURE CODE [CA1673] .1239
FAILURE CODE [CA1677] .1240
FAILURE CODE [CA1678] .1241
FAILURE CODE [CA1682] .1242
FAILURE CODE [CA1683] .1246
FAILURE CODE [CA1684] .1248
FAILURE CODE [CA1686] .1250
FAILURE CODE [CA1691] .1251
FAILURE CODE [CA1694] .1254
FAILURE CODE [CA1695] .1257
FAILURE CODE [CA1696] .1258
FAILURE CODE [CA1712] .1260
FAILURE CODE [CA1713] .1263
FAILURE CODE [CA1714] .1265
FAILURE CODE [CA1715] .1266
FAILURE CODE [CA1776] .1267
FAILURE CODE [CA1777] .1270
FAILURE CODE [CA1843] .1273
FAILURE CODE [CA1844] .1275
FAILURE CODE [CA1879] .1278
FAILURE CODE [CA1881] .1281
FAILURE CODE [CA1883] .1283
FAILURE CODE [CA1885] .1287
FAILURE CODE [CA1887] .1289
FAILURE CODE [CA1921] .1291
FAILURE CODE [CA1922] .1294
FAILURE CODE [CA1942] .1299
FAILURE CODE [CA1993] .1300
FAILURE CODE [CA2185] .1303
FAILURE CODE [CA2186] .1305
FAILURE CODE [CA2249] .1307
FAILURE CODE [CA2271] .1308
FAILURE CODE [CA2272] .1311
FAILURE CODE [CA2288] .1314
FAILURE CODE [CA2311] .1315
FAILURE CODE [CA2349] .1316
FAILURE CODE [CA2353] .1319
FAILURE CODE [CA2357] .1321
FAILURE CODE [CA2381] .1322
FAILURE CODE [CA2382] .1325
FAILURE CODE [CA2383] .1328
FAILURE CODE [CA2386] .1331
FAILURE CODE [CA2387] .1333
TROUBLESHOOTING FLOWCHART .1337
FAILURE CODE [CA2555] .1338
FAILURE CODE [CA2556] .1341
FAILURE CODE [CA2637] .1344
FAILURE CODE [CA2639] .1346
FAILURE CODE [CA2771] .1349
FAILURE CODE [CA2777] .1355
FAILURE CODE [CA2976] .1358
FAILURE CODE [CA3133] .1360
FAILURE CODE [CA3134] .1362
FAILURE CODE [CA3135] .1364
FAILURE CODE [CA3142] .1368
FAILURE CODE [CA3143] .1369
FAILURE CODE [CA3144] .1370
FAILURE CODE [CA3146] .1372
FAILURE CODE [CA3147] .1373
FAILURE CODE [CA3148] .1374
FAILURE CODE [CA3151] .1376
FAILURE CODE [CA3165] .1382
FAILURE CODE [CA3229] .1385
FAILURE CODE [CA3231] .1387
FAILURE CODE [CA3232] .1389
FAILURE CODE [CA3235] .1393
FAILURE CODE [CA3239] .1395
FAILURE CODE [CA3241] .1398
FAILURE CODE [CA3242] .1401
FAILURE CODE [CA3251] .1404
FAILURE CODE [CA3253] .1406
FAILURE CODE [CA3254] .1409
FAILURE CODE [CA3255] .1412
FAILURE CODE [CA3256] .1415
FAILURE CODE [CA3311] .1417
FAILURE CODE [CA3312] .1419
FAILURE CODE [CA3313] .1422
FAILURE CODE [CA3314] .1423
FAILURE CODE [CA3315] .1424
FAILURE CODE [CA3316] .1427
FAILURE CODE [CA3317] .1428
FAILURE CODE [CA3318] .1429
FAILURE CODE [CA3319] .1432
FAILURE CODE [CA3321] .1433
FAILURE CODE [CA3322] .1435
FAILURE CODE [CA3419] .1438
FAILURE CODE [CA3421] .1440
FAILURE CODE [CA3497] .1442
FAILURE CODE [CA3498] .1443
FAILURE CODE [CA3543] .1444
FAILURE CODE [CA3545] .1451
FAILURE CODE [CA3547] .1453
FAILURE CODE [CA3558] .1454
FAILURE CODE [CA3559] .1456
FAILURE CODE [CA3562] .1458
FAILURE CODE [CA3563] .1460
FAILURE CODE [CA3567] .1463
FAILURE CODE [CA3568] .1467
FAILURE CODE [CA3571] .1473
FAILURE CODE [CA3572] .1475
FAILURE CODE [CA3574] .1477
FAILURE CODE [CA3575] .1480
FAILURE CODE [CA3577] .1482
FAILURE CODE [CA3578] .1484
FAILURE CODE [CA3582] .1486
FAILURE CODE [CA3583] .1494
FAILURE CODE [CA3596] .1496
FAILURE CODE [CA3649] .1499
FAILURE CODE [CA3681] .1501
FAILURE CODE [CA3682] .1506
FAILURE CODE [CA3713] .1512
FAILURE CODE [CA3717] .1515
FAILURE CODE [CA3718] .1516
FAILURE CODE [CA3725] .1517
FAILURE CODE [CA3741] .1520
FAILURE CODE [CA3748] .1521
FAILURE CODE [CA3751] .1523
FAILURE CODE [CA3755] .1525
FAILURE CODE [CA3866] .1527
FAILURE CODE [CA3867] .1531
FAILURE CODE [CA3868] .1534
FAILURE CODE [CA3899] .1538
FAILURE CODE [CA3911] .1540
FAILURE CODE [CA3912] .1544
FAILURE CODE [CA3932] .1546
FAILURE CODE [CA3933] .1548
FAILURE CODE [CA3934] .1550
FAILURE CODE [CA3935] .1553
FAILURE CODE [CA3936] .1555
FAILURE CODE [CA4151] .1557
FAILURE CODE [CA4152] .1561
FAILURE CODE [CA4155] .1565
FAILURE CODE [CA4156] .1568
FAILURE CODE [CA4157] .1571
FAILURE CODE [CA4158] .1573
FAILURE CODE [CA4159] .1574
FAILURE CODE [CA4161] .1575
FAILURE CODE [CA4162] .1578
FAILURE CODE [CA4163] .1581
FAILURE CODE [CA4164] .1583
FAILURE CODE [CA4165] .1585
FAILURE CODE [CA4166] .1587
FAILURE CODE [CA4168] .1589
FAILURE CODE [CA4169] .1592
FAILURE CODE [CA4171] .1594
FAILURE CODE [CA4249] .1597
FAILURE CODE [CA4251] .1599
FAILURE CODE [CA4259] .1601
FAILURE CODE [CA4261] .1604
FAILURE CODE [CA4277] .1607
FAILURE CODE [CA4281] .1611
FAILURE CODE [CA4459] .1614
FAILURE CODE [CA4461] .1617
FAILURE CODE [CA4658] .1620
FAILURE CODE [CA4731] .1624
FAILURE CODE [CA4732] .1625
FAILURE CODE [CA4739] .1626
FAILURE CODE [CA4768] .1627
FAILURE CODE [CA4769] .1629
FAILURE CODE [CA4842] .1632
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) .1636
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1638
FAILURE CODE [CA5115] .1640
FAILURE CODE [CA5383] .1643
FAILURE CODE [D130KA] .1645
FAILURE CODE [D130KB] .1648
FAILURE CODE [D130KY] .1650
FAILURE CODE [D19JKZ] .1652
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) .1655
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1656
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) .1657
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1658
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) .1659
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1661
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) .1663
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1665
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) .1667
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1669
FAILURE CODE [D8G1KT] .1671
FAILURE CODE [D8G6KT] .1672
FAILURE CODE [DAF0MB] .1673
FAILURE CODE [DAF0MC] .1674
FAILURE CODE [DAF8KB] .1675
FAILURE CODE [DAF9KQ] .1677
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL) .1678
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1679
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) .1680
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1682
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) .1684
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1686
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) .1688
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1689
FAILURE CODE [DAJ000] .1690
FAILURE CODE [DAJ0KQ] .1691
FAILURE CODE [DAJ0KT] .1692
FAILURE CODE [DAJ0MC] .1693
FAILURE CODE [DAJ1KK] .1694
FAILURE CODE [DAJ2KK] .1696
FAILURE CODE [DAJ5KK] .1698
FAILURE CODE [DAJ6KK] .1701
FAILURE CODE [DAJLKA] (MACHINE WITH KOMTRAX TERMINAL) .1703
FAILURE CODE [DAJLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1705
FAILURE CODE [DAJLKB] (MACHINE WITH KOMTRAX TERMINAL) .1707
FAILURE CODE [DAJLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1709
FAILURE CODE [DAJPMA] .1711
FAILURE CODE [DAJQKR] (MACHINE WITH KOMTRAX TERMINAL) .1712
FAILURE CODE [DAJQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1713
FAILURE CODE [DAJRKR] .1714
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) .1715
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1720
FAILURE CODE [DB2RKR] (MACHINE WITH KOMTRAX TERMINAL) .1725
FAILURE CODE [DB2RKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1730
FAILURE CODE [DBR0KT] .1735
FAILURE CODE [DBR0MC] .1736
FAILURE CODE [DBR1KK] .1737
FAILURE CODE [DBR2KK] .1740
FAILURE CODE [DBR5KK] .1743
FAILURE CODE [DBRLKA] .1745
FAILURE CODE [DBRLKB] .1747
FAILURE CODE [DBRPMA] .1749
FAILURE CODE [DBRQKR] .1750
FAILURE CODE [DBRRKR] .1752
FAILURE CODE [DBTSKR] .1753
FAILURE CODE [DBUTKA] .1756
FAILURE CODE [DD12KA] .1757
FAILURE CODE [DD12KB] .1759
FAILURE CODE [DD13KA] .1761
FAILURE CODE [DD13KB] .1763
FAILURE CODE [DD14KA] .1765
FAILURE CODE [DD14KB] .1767
FAILURE CODE [DDKAKA] .1769
FAILURE CODE [DDKAKB] .1771
FAILURE CODE [DDKFL4] .1773
FAILURE CODE [DDKGL4] .1775
FAILURE CODE [DDKHKA] .1777
FAILURE CODE [DDKHKB] .1779
FAILURE CODE [DDKQKA] .1781
FAILURE CODE [DDKQKB] .1783
FAILURE CODE [DDKRKA] .1785
FAILURE CODE [DDKRKB] .1787
FAILURE CODE [DDKSKA] .1789
FAILURE CODE [DDKSKB] .1791
FAILURE CODE [DDNLKA] .1793
FAILURE CODE [DDNLKB] .1795
FAILURE CODE [DDP6KA] .1797
FAILURE CODE [DDP6KB] .1800
FAILURE CODE [DDP6MA] .1802
FAILURE CODE [DDU1FS] .1804
FAILURE CODE [DDU1KA] .1806
FAILURE CODE [DDU1KY] .1809
FAILURE CODE [DFA4KX] .1811
FAILURE CODE [DFA4KZ] .1812
FAILURE CODE [DFA4L8] .1813
FAILURE CODE [DFA5KA] .1814
FAILURE CODE [DFA5KB] .1817
FAILURE CODE [DFA6KA] .1820
FAILURE CODE [DFA6KB] .1823
FAILURE CODE [DFA7KX] .1826
FAILURE CODE [DFA7KZ] .1827
FAILURE CODE [DFA7L8] .1828
FAILURE CODE [DFA8KA] .1829
FAILURE CODE [DFA8KB] .1832
FAILURE CODE [DFA9KA] .1835
FAILURE CODE [DFA9KB] .1838
FAILURE CODE [DGS1KA] .1841
FAILURE CODE [DGS1KX] .1844
FAILURE CODE [DH21KA] .1845
FAILURE CODE [DH21KB] .1847
FAILURE CODE [DHA4KA] .1849
FAILURE CODE [DHAAMA] .1851
FAILURE CODE [DHACMA] .1853
FAILURE CODE [DHH7KA] .1855
FAILURE CODE [DHH7KB] .1858
FAILURE CODE [DHH8KA] .1860
FAILURE CODE [DHH8KB] .1863
FAILURE CODE [DHH9KA] .1865
FAILURE CODE [DHH9KB] .1868
FAILURE CODE [DHHAKA] .1870
FAILURE CODE [DHHAKB] .1873
FAILURE CODE [DK30KA] .1875
FAILURE CODE [DK30KB] .1878
FAILURE CODE [DK30KX] .1880
FAILURE CODE [DK30KZ] .1881
FAILURE CODE [DK30L8] .1882
FAILURE CODE [DK31KA] .1883
FAILURE CODE [DK31KB] .1886
FAILURE CODE [DK40KA] .1888
FAILURE CODE [DK40KB] .1891
FAILURE CODE [DK55KX] .1893
FAILURE CODE [DK55KZ] .1894
FAILURE CODE [DK55L8] .1895
FAILURE CODE [DK56KA] .1896
FAILURE CODE [DK56KB] .1899
FAILURE CODE [DK57KA] .1901
FAILURE CODE [DK57KB] .1904
FAILURE CODE [DK80KA] .1906
FAILURE CODE [DKS0L8] .1909
FAILURE CODE [DKS1KA] .1910
FAILURE CODE [DKS1KB] .1912
FAILURE CODE [DKS2KA] .1914
FAILURE CODE [DKS2KB] .1916
FAILURE CODE [DKS3KA] .1918
FAILURE CODE [DKS3KB] .1920
FAILURE CODE [DKS3MB] .1922
FAILURE CODE [DKS4L8] .1924
FAILURE CODE [DKS5KA] .1925
FAILURE CODE [DKS5KB] .1927
FAILURE CODE [DKS6KA] .1929
FAILURE CODE [DKS6KB] .1931
FAILURE CODE [DKS7MB] .1933
FAILURE CODE [DKSCL8] .1934
FAILURE CODE [DKSDKA] .1935
FAILURE CODE [DKSDKB] .1937
FAILURE CODE [DKSEKA] .1939
FAILURE CODE [DKSEKB] .1941
FAILURE CODE [DKSFMB] .1943
FAILURE CODE [DLM0KX] .1944
FAILURE CODE [DLM0MA] .1945
FAILURE CODE [DLM1KA] .1946
FAILURE CODE [DLM1KB] .1948
FAILURE CODE [DLM1MA] .1950
FAILURE CODE [DLM2KA] .1951
FAILURE CODE [DLM2KB] .1953
FAILURE CODE [DLM2MA] .1955
FAILURE CODE [DLM3KA] .1956
FAILURE CODE [DLM3KB] .1958
FAILURE CODE [DLM3MB] .1960
FAILURE CODE [DN21FS] .1961
FAILURE CODE [DR21KX] .1963
FAILURE CODE [DR31KX] .1964
FAILURE CODE [DV20KB] .1965
FAILURE CODE [DW4BKA] .1967
FAILURE CODE [DW4BKB] .1969
FAILURE CODE [DW4BKY] .1971
FAILURE CODE [DW7BKA] .1973
FAILURE CODE [DW7BKB] .1975
FAILURE CODE [DW7EKA] .1977
FAILURE CODE [DW7EKB] .1979
FAILURE CODE [DW7EKY] .1981
FAILURE CODE [DWN5KA] .1983
FAILURE CODE [DWN5KB] .1985
FAILURE CODE [DWN5KY] .1987
FAILURE CODE [DXA4KA] .1989
FAILURE CODE [DXA4KB] .1991
FAILURE CODE [DXA4KY] .1993
FAILURE CODE [DXA5KA] .1995
FAILURE CODE [DXA5KB] .1997
FAILURE CODE [DXA5KY] .1999
FAILURE CODE [DXA6KA] .2001
FAILURE CODE [DXA6KB] .2003
FAILURE CODE [DXA6KY] .2005
FAILURE CODE [DXA7KA] .2007
FAILURE CODE [DXA7KB] .2009
FAILURE CODE [DXA7KY] .2011
FAILURE CODE [DXHRKA] .2013
FAILURE CODE [DXHRKB] .2015
FAILURE CODE [DXHRKY] .2017
FAILURE CODE [DXHSKA] .2019
FAILURE CODE [DXHSKB] .2021
FAILURE CODE [DXHSKY] .2023
FAILURE CODE [DXHTKA] .2025
FAILURE CODE [DXHTKB] .2027
FAILURE CODE [DXHTKY] .2029
FAILURE CODE [DXHUKA] .2031
FAILURE CODE [DXHUKB] .2033
FAILURE CODE [DXHUKY] .2035
FAILURE CODE [DXJ4KA] .2037
FAILURE CODE [DXJ4KB] .2039
FAILURE CODE [DXJCKA] .2041
FAILURE CODE [DXJCKB] .2043
FAILURE CODE [DXJCKY] .2045
FAILURE CODE [DXJDKA] .2047
FAILURE CODE [DXJDKB] .2049
FAILURE CODE [DXJDKY] .2051
FAILURE CODE [DXK1KA] .2053
FAILURE CODE [DXK1KB] .2055
FAILURE CODE [DXK1KY] .2057
FAILURE CODE [DXK2KA] .2059
FAILURE CODE [DXK2KB] .2061
FAILURE CODE [DXK2KY] .2063
FAILURE CODE [F313KA] .2065
FAILURE CODE [F313KB] .2066
FAILURE CODE [F318KB] .2067
FAILURE CODE [F318KY] .2068
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .2069
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .2069
MANUAL PREHEATING SYSTEM DOES NOT WORK 2076
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .2079
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .2081
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .2083
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 2087
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2088
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2089
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2090
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2091
HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2092
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2093
HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2094
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2095
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2096
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .2099
OPERATION MODE DOES NOT CHANGE 2100
OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 2101
MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 2102
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2103
SERVICE MODE CANNOT BE SELECTED .2104
WORK EQUIPMENT DOES NOT OPERATE .2105
FOOT HEATER DOES NOT OPERATE 2107
HORN DOES NOT SOUND .2113
HORN DOES NOT STOP SOUNDING .2115
BACKUP ALARM DOES NOT SOUND .2116
BACKUP ALARM DOES NOT STOP SOUNDING .2117
HEADLAMP DOES NOT LIGHT UP 2118
REAR LAMP DOES NOT LIGHT UP .2122
ALL WIPERS DO NOT OPERATE .2125
FRONT WIPER DOES NOT OPERATE 2127
REAR WIPER DOES NOT OPERATE .2129
LEFT DOOR WIPER DOES NOT OPERATE 2131
RIGHT DOOR WIPER DOES NOT OPERATE .2135
FRONT WASHER DOES NOT OPERATE .2139
REAR WASHER DOES NOT OPERATE 2141
LEFT DOOR WASHER DOES NOT OPERATE .2143
RIGHT DOOR WASHER DOES NOT OPERATE 2145
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2147
CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !] 2148
CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !] .2152
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link .] 2157
CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected] .2158
CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites .] 2159
CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] 2160
CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal] .2162
CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal] .2163
CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble] 2164
CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize ] 2165
CONTROL BOX DISPLAYS THE MESSAGE [System Initializing] 2166
CONTROL BOX DISPLAYS THE MESSAGE [Initializing ] .2167
CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS] 2168
CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization .] .2169
CONTROL BOX DISPLAYS THE MESSAGE [Low precisions .] 2170
CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing] .2171
CONTROL BOX DISPLAYS [Out of design area .] 2172
CONTROL BOX CAN NOT BE TURNED ON 2173
CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN .2174
CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE 2175
CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE .2176
CONTROL BOX TOUCH PANEL DOES NOT RESPOND 2177
CONTROL BOX TOUCH PANEL IS INACCURATE .2178
CYLINDER STROKE RESET INDICATION DOES NOT GO OUT 2179
AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT) .2180
BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2182
BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2183
BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS) .2184
WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE .2185
FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) 2186
FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH) .2187
FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION) 2188
MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS) 2190
MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED 2191
BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE 2192
BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED .2194
WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT 2196
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .2198
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .2198
FAILURE MODE AND CAUSE TABLE 2199
NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) 2205
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) .2207
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) .2209
TRAVEL SPEED OR POWER IS LOW 2211
SPEED RANGE DOES NOT CHANGE .2213
SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS 2214
MACHINE DEVIATES LARGELY 2215
MACHINE DRIFT ON A SLOPE IS LARGE .2218
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2220
UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 2222
HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 2224
ALL WORK EQUIPMENT DO NOT OPERATE .2226
ALL WORK EQUIPMENTS SPEED OR POWER IS LOW .2228
BLADE LIFT SPEED OR POWER IS LOW 2229
BLADE TILT SPEED OR POWER IS LOW 2231
BLADE ANGLE SPEED OR POWER IS LOW .2232
TIME LAG OF BLADE LIFT IS LARGE .2233
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 2234
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 2235
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE .2236
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2237
UNUSUAL NOISE IS HEARD FROM AROUND FAN 2239
TROUBLESHOOTING OF ENGINE (S-MODE) 2240
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2240
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2241
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2242
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2243
ENGINE STARTABILITY IS POOR .2245
ENGINE DOES NOT PICK UP SMOOTHLY 2247
ENGINE STOPS DURING OPERATION .2249
ENGINE RUNS ROUGH OR IS UNSTABLE 2251
ENGINE LACKS POWER 2252
KDPF GETS CLOGGED IN A SHORT TIME .2254
ENGINE OIL CONSUMPTION IS EXCESSIVE .2256
OIL BECOMES CONTAMINATED QUICKLY 2257
FUEL CONSUMPTION IS EXCESSIVE .2258
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .2259
OIL PRESSURE DROPS 2260
FUEL MIXES INTO ENGINE OIL 2262
WATER MIXES INTO ENGINE OIL (MILKY) .2263
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2264
UNUSUAL NOISE IS HEARD 2265
VIBRATION IS EXCESSIVE 2266
AIR CANNOT BE BLED FROM FUEL CIRCUIT 2267
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2268
ACTIVE REGENERATION TAKES TIME 2270
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .2271
AdBlue/DEF CONSUMPTION IS EXCESSIVE .2272
THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2274
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) .2275
50 DISASSEMBLY AND ASSEMBLY .2277
CONTENTS 2278
ABBREVIATION LIST .2284
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2290
HOW TO READ THIS MANUAL .2290
COATING MATERIALS LIST 2292
SPECIAL TOOLS LIST 2296
SKETCHES OF SPECIAL TOOLS .2317
ENGINE AND COOLING SYSTEM .2330
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2330
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2331
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2336
REMOVE AND INSTALL INJECTOR ASSEMBLY 2343
METHOD FOR REMOVING INJECTOR ASSEMBLY .2343
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2350
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2360
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2360
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2372
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2390
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2390
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2391
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2393
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2393
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2395
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2398
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY .2398
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY .2400
REMOVE AND INSTALL ALTERNATOR BELT 2402
METHOD FOR REMOVING ALTERNATOR BELT .2402
METHOD FOR INSTALLING ALTERNATOR BELT .2403
REMOVE AND INSTALL AUTOMATIC TENSIONER 2405
METHOD FOR REMOVING AUTOMATIC TENSIONER .2405
METHOD FOR INSTALLING AUTOMATIC TENSIONER .2405
REMOVE AND INSTALL RADIATOR ASSEMBLY 2406
METHOD FOR REMOVING RADIATOR ASSEMBLY .2406
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2409
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2413
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2413
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2416
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2419
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2419
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2422
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY .2426
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2426
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2429
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY .2433
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2433
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2436
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY 2440
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY .2440
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY .2449
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2460
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2460
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2461
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2463
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2463
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2465
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2468
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2468
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2471
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2475
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2475
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2481
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2487
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2487
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2493
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2499
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2499
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2500
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2503
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2503
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2504
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2511
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2511
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2512
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2513
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2513
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2514
REMOVE AND INSTALL KDPF ASSEMBLY 2517
METHOD FOR REMOVING KDPF ASSEMBLY .2518
METHOD FOR INSTALLING KDPF ASSEMBLY .2521
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2524
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2524
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2527
REMOVE AND INSTALL SCR ASSEMBLY .2534
METHOD FOR REMOVING SCR ASSEMBLY 2534
METHOD FOR INSTALLING SCR ASSEMBLY 2536
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2540
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2541
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2547
REMOVE AND INSTALL KCCV ASSEMBLY 2554
METHOD FOR REMOVING KCCV ASSEMBLY .2554
METHOD FOR INSTALLING KCCV ASSEMBLY .2556
REMOVE AND INSTALL VGT ASSEMBLY .2558
METHOD FOR REMOVING VGT ASSEMBLY 2558
METHOD FOR INSTALLING VGT ASSEMBLY 2560
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2563
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2564
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2566
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2570
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2570
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2573
REMOVE AND INSTALL AdBlue/DEF PUMP 2577
METHOD FOR REMOVING AdBlue/DEF PUMP .2577
METHOD FOR INSTALLING AdBlue/DEF PUMP .2580
REMOVE AND INSTALL AdBlue/DEF HOSE 2583
METHOD FOR REMOVING AdBlue/DEF HOSE .2583
METHOD FOR INSTALLING AdBlue/DEF HOSE .2587
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2593
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2593
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2595
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2598
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2598
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2599
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2601
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2601
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2605
POWER TRAIN .2609
REMOVE AND INSTALL DAMPER ASSEMBLY 2609
METHOD FOR REMOVING DAMPER ASSEMBLY .2609
METHOD FOR INSTALLING DAMPER ASSEMBLY .2610
REMOVE AND INSTALL HST PUMP ASSEMBLY 2612
METHOD FOR REMOVING HST PUMP ASSEMBLY .2612
METHOD FOR INSTALLING HST PUMP ASSEMBLY .2614
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY .2616
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY 2616
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY 2619
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY . 0
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2624
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2629
UNDERCARRIAGE AND FRAME .2638
REMOVE AND INSTALL TRACK FRAME ASSEMBLY .2638
METHOD FOR REMOVING TRACK FRAME ASSEMBLY 2638
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY 2642
REMOVE AND INSTALL IDLER ASSEMBLY .2647
METHOD FOR REMOVING IDLER ASSEMBLY 2647
METHOD FOR INSTALLING IDLER ASSEMBLY 2649
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2651
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2651
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2653
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY .2658
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2658
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2659
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY .2660
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY 2660
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY 2663
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2666
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY .2666
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY .2667
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2670
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2670
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2672
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2676
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY .2676
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY .2677
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2679
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2679
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2680
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY .2683
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2683
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2684
SEPARATE AND CONNECT TRACK ASSEMBLY .2686
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY 2686
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) .2687
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) .2688
METHOD FOR CONNECTING TRACK ASSEMBLY 2689
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY .2691
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2691
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2691
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY .2693
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY .2693
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2698
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY .2711
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .2712
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2713
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2728
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2729
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2730
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2737
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2738
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2740
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY .2744
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 2744
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 2746
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS 2749
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS .2749
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS .2749
REMOVE AND INSTALL SEGMENT TEETH 2751
METHOD FOR REMOVING SEGMENT TEETH .2751
METHOD FOR INSTALLING SEGMENT TEETH .2752
HYDRAULIC SYSTEM 2753
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2753
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2754
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2758
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2763
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2763
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2768
WORK EQUIPMENT 2773
REMOVE AND INSTALL BLADE ASSEMBLY .2773
METHOD FOR REMOVING BLADE ASSEMBLY 2773
METHOD FOR INSTALLING BLADE ASSEMBLY 2775
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2779
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2779
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2783
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2786
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY .2786
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY .2788
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2791
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 2792
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY .2796
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2804
METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY .2804
METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY .2807
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2812
METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY 2813
METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY .2816
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY .2821
METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2821
METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2824
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY .2827
METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY .2828
METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY 2831
REMOVE AND INSTALL U-FRAME ASSEMBLY .2837
METHOD FOR REMOVING U-FRAME ASSEMBLY 2837
METHOD FOR INSTALLING U-FRAME ASSEMBLY 2840
CAB AND ITS ATTACHMENTS .2843
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2843
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2843
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2851
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) .2859
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2861
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2861
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2867
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2867
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2873
REMOVE AND INSTALL OPERATOR’S SEAT 2880
METHOD FOR REMOVING OPERATOR’S SEAT .2880
METHOD FOR INSTALLING OPERATOR’S SEAT .2881
REMOVE AND INSTALL SEAT BELT 2882
METHOD FOR REMOVING SEAT BELT .2882
METHOD FOR INSTALLING SEAT BELT .2882
REMOVE AND INSTALL FOOT HEATER ASSEMBLY .2884
METHOD FOR REMOVING FOOT HEATER ASSEMBLY 2884
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY 2886
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY .2889
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY .2889
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY 2890
ELECTRICAL SYSTEM .2891
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2891
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2891
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2893
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 2896
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY .2896
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY .2897
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2898
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2898
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2899
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2901
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2901
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2903
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2904
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2904
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2906
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2908
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2908
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2909
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2911
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2911
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2912
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2913
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY .2913
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2914
REMOVE AND INSTALL COMMUNICATION TERMINAL .2915
REMOVE COMMUNICATION TERMINAL .2915
INSTALL COMMUNICATION TERMINAL 2918
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY .2921
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY 2921
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY 2921
REMOVE AND INSTALL CONTROL BOX 2923
METHOD FOR REMOVING CONTROL BOX (FOR OLD CONTROL BOX) .2923
METHOD FOR REMOVING CONTROL BOX (FOR NEW CONTROL BOX) .2924
METHOD FOR INSTALLING CONTROL BOX (FOR OLD CONTROL BOX) .2924
METHOD FOR INSTALLING CONTROL BOX (FOR NEW CONTROL BOX) .2925
REMOVE AND INSTALL GNSS RECEIVER 2927
METHOD FOR REMOVING GNSS RECEIVER .2927
METHOD FOR INSTALLING GNSS RECEIVER .2927
REMOVE AND INSTALL GNSS ANTENNA .2929
METHOD FOR REMOVING GNSS ANTENNA 2929
METHOD FOR INSTALLING GNSS ANTENNA 2930
REMOVE AND INSTALL IMU SENSOR .2935
METHOD FOR REMOVING IMU SENSOR 2935
METHOD FOR INSTALLING IMU SENSOR 2937
60 MAINTENANCE STANDARD .2940
CONTENTS 2941
ABBREVIATION LIST .2943
ENGINE AND COOLING SYSTEM .2949
MAINTENANCE STANDARD OF ENGINE MOUNT 2949
MAINTENANCE STANDARD OF DAMPER 2950
MAINTENANCE STANDARD OF COOLING SYSTEM 2951
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2953
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP .2955
POWER TRAIN .2956
MAINTENANCE STANDARD OF HST PUMP 2956
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP .2957
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP .2958
MAINTENANCE STANDARD OF HST CHARGE PUMP .2959
MAINTENANCE STANDARD OF HST MOTOR .2961
MAINTENANCE STANDARD OF FINAL DRIVE .2962
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE .2964
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 2965
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE .2967
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 2968
UNDERCARRIAGE AND FRAME .2970
MAINTENANCE STANDARD OF SUSPENSION 2970
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2972
MAINTENANCE STANDARD OF IDLER .2974
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) .2976
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) .2977
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) .2978
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) .2979
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE .2980
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE .2981
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 2982
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2984
MAINTENANCE STANDARD OF SINGLE SHOE .2986
MAINTENANCE STANDARD OF SWAMP SHOE 2987
HYDRAULIC SYSTEM 2988
MAINTENANCE STANDARD OF HYDRAULIC TANK 2988
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP .2989
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP 2990
MAINTENANCE STANDARD OF CONTROL VALVE .2992
MAINTENANCE STANDARD OF RIPPER PPC VALVE 2999
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID 3001
MAINTENANCE STANDARD OF EPC VALVE .3002
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE .3003
MAINTENANCE STANDARD OF QUICK DROP VALVE 3004
WORK EQUIPMENT 3006
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 3006
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 3009
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER .3010
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER 3011
MAINTENANCE STANDARD OF BLADE TILT CYLINDER .3012
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER 3013
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER 3014
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER .3015
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER .3016
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER .3017
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER 3018
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 3019
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 3021
CAB AND ITS ATTACHMENTS .3022
MAINTENANCE STANDARD OF CAB MOUNT .3022
ELECTRICAL SYSTEM .3023
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER .3023
80 APPENDIX .3024
CONTENTS 3025
ABBREVIATION LIST .3026
AIR CONDITIONER SYSTEM 3032
PRECAUTIONS FOR REFRIGERANT .3032
AIR CONDITIONER COMPONENT .3033
SPECIFICATIONS OF AIR CONDITIONER .3036
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .3037
OUTLINE OF REFRIGERATION CYCLE 3038
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .3040
AIR CONDITIONER UNIT 3040
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .3040
FUNCTION OF AIR CONDITIONER UNIT 3041
COMPONENT PARTS OF AIR CONDITIONER UNIT .3042
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3042
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .3042
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT 3042
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3043
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3043
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3043
FUNCTION OF DUAL PRESSURE SWITCH 3044
FUNCTION OF PRESSURE SWITCH .3044
COMPRESSOR 3045
STRUCTURE OF COMPRESSOR .3045
SPECIFICATIONS OF COMPRESSOR 3045
FUNCTION OF COMPRESSOR 3045
CONDENSER .3046
STRUCTURE OF CONDENSER 3046
SPECIFICATIONS OF CONDENSER .3046
FUNCTION OF CONDENSER .3047
RECEIVER DRIER 3048
STRUCTURE OF RECEIVER DRIER .3048
SPECIFICATIONS OF RECEIVER DRIER 3048
FUNCTION OF RECEIVER DRIER 3048
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .3050
CIRCUIT DIAGRAM OF AIR CONDITIONER 3053
AIR CONDITIONER SYSTEM DIAGRAM 3054
CONTROL FUNCTION OF AIR CONDITIONER .3055
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .3056
TEST RELAYS .3060
METHOD FOR TESTING RELAYS .3060
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3062
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3063
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3066
TROUBLESHOOTING FOR CONDENSER FAN .3068
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3071
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3075
TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 3078
TROUBLESHOOTING USING GAUGE PRESSURE 3082
CONNECTION OF SERVICE TOOL 3084
METHOD FOR CONNECTING SERVICE TOOL 3084
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3085
HANDLE COMPRESSOR OIL .3087
90 CIRCUIT DIAGRAMS .3090
CONTENTS 3091
ABBREVIATION LIST .3092
HYDRAULIC CIRCUIT DIAGRAM .3098
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3098
HYDRAULIC CIRCUIT DIAGRAM .3102
ELECTRICAL CIRCUIT DIAGRAM 3104
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3104
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (1/14) .3108
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (2/14) .3110
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (3/14) .3112
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (4/14) .3114
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (5/14) .3116
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (6/14) .3118
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (7/14) .3120
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (8/14) .3122
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (9/14) .3124
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (10/14) 3126
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (11/14) 3128
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (12/14) 3130
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (13/14) 3132
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (14/14) 3134
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/16) 3136
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/16) 3138
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/16) 3140
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/16) 3142
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/16) 3144
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/16) 3146
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/16) 3148
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/16) 3150
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/16) 3152
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/16) .3154
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (11/16) .3156
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (12/16) .3158
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (13/16) .3160
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (14/16) .3162
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (15/16) .3164
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (16/16) .3166
INDEX 3168

DESCRIPTION:

Komatsu D61EXi-24,D61PXi-24 Bulldozer Shop Manual KEBM657808  – PDF DOWNLOAD

SERIAL NUMBERS

• D61EXi-B60001  and up
• D61PXi-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