Komatsu D71EX-24 D71EX-24E0 D71PX-24 D71PX-24E0 Bulldozer Shop Manual SEN06841-09 PDF

Description

Komatsu D71EX-24 D71EX-24E0 D71PX-24 D71PX-24E0 Bulldozer Shop Manual SEN06841-09 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D71EX-24 D71EX-24E0 D71PX-24 D71PX-24E0 Bulldozer Shop Manual SEN06841-09 – PDF DOWNLOAD 

Language : English
Pages : 3384
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D71EX-24 D71EX-24E0 D71PX-24 D71PX-24E0 Bulldozer Shop Manual SEN06841-09 – PDF DOWNLOAD 

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 Specification
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.

TABLE OF CONTENTS:

Komatsu D71EX-24 D71EX-24E0 D71PX-24 D71PX-24E0 Bulldozer Shop Manual SEN06841-09 – PDF DOWNLOAD

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 23
How to Read the Shop Manual 23
Safety Notice for Operation 25
Precautions to Prevent Fire 33
Procedures If Fire Occurs 35
Precautions for Disposing of Waste Materials 36
Procedures for Exhaust Gas Regulations 37
Precautions for DEF 38
General Character and Precautions for Handling 38
Precautions for Adding 38
Precautions for Storage 38
Precautions for Fire Hazard and Leakage 38
Other Precautions 38
Store DEF 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors 59
How to Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
How to Disconnect and Connect Connector with Lock to Pull 66
How to Disconnect and Connect Connector with Lock to Push 67
How to Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
Abbreviation List 89
01 Specifications 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: D71EX-24, D71EX-24E0 95
Specification Drawing: D71PX-24, D71PX-24E0 97
Specification Drawing: D71PX-24, D71PX-24E0 (Wide Gauge Specification) 99
Specifications 101
Specifications: D71EX-24, D71EX-24E0 101
Specifications: D71PX-24, D71PX-24E0 106
Specifications: D71PX-24, D71PX-24E0 (Wide Gauge Specification) 111
Weight Table 116
Weight Table: D71EX-24, D71EX-24E0 116
Weight Table: D71PX-24, D71PX-24E0 118
Weight Table: D71PX-24, D71PX-24E0 (Wide Gauge Specification) 120
Fuel, Coolant, Lubricants (For North America) 122
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 122
Fuel, Coolant, Lubricants (For European Union) 124
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 124
10 Structure and Function 127
Table of Contents 128
Urea SCR System 131
Layout Drawing of Urea SCR System 131
Urea SCR System Diagram 133
Function of Urea SCR System 134
Function of DEF System (Applicable Machine: 70002 to 70281) 134
Function of DEF System (Applicable Machine: 70282 and Up) 136
Inducement Strategy 138
Component Parts of Urea SCR System 152
DEF Mixing Tube 152
SCR Assembly 153
DEF Tank 155
DEF Pump 157
DEF Injector 158
DEF Hose 159
DEF Tank Heating Valve 160
Boot-up System 161
Layout Drawing of Boot-up System 161
System Operating Lamp System 162
System Diagram of System Operating Lamp System 162
Function of System Operating Lamp System (Applicable Machine: 70002 to 70281) 162
Function of System Operating Lamp System (Applicable Machine: 70282 and Up) 163
Battery Disconnect Switch 165
Function of Battery Disconnect Switch (Applicable Machine: 70002 to 70281) 165
Function of Battery Disconnect Switch (Applicable Machine: 70282 and Up) 165
Operation of Battery Disconnect Switch 165
Assistance Valve for Startup 167
Structure of Assistance Valve for Startup 167
Function of Assistance Valve for Startup 167
Engine System 168
Layout Drawing of Engine System 168
Engine Control System 170
Layout Drawing of Engine Control System 170
System Diagram of Engine Control 172
Function of Engine Control System 173
Engine Automatic Warm-up System 175
Function of Engine Automatic Warm-up System 175
Automatic Idle Stop System 176
System Diagram of Automatic Idle Stop System 176
Function of Automatic Idle Stop System 176
Component Parts of Engine System 179
Damper 179
VGT 180
EGR System 184
EGR Valve 186
EGR Cooler 188
KCCV System 190
KCCV Ventilator 192
KDPF 194
Cooling System 198
Layout Drawing of Cooling System 198
Specifications of Cooling System 199
Cooling Fan Control System 200
System Diagram of Cooling Fan Control System 200
Function of Cooling Fan Control System 200
Component Parts of Cooling System 202
Cooling Fan Motor 202
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 208
Hydraulic Oil Cooler Bypass Valve 210
HST Charge Safety Valve 211
Control System 213
Layout Drawing of Control System 213
Machine Monitor System 214
System Diagram of Machine Monitor System 214
Function of Machine Monitor System 214
KOMTRAX System 216
System Diagram of KOMTRAX System 216
Function of KOMTRAX System 216
Component Parts of Control System 217
Machine Monitor 217
Gateway Function Controller 236
Communication Terminal 239
HST Controller 241
Work Equipment Controller 245
Engine Controller 249
Fuel Control Dial 256
Deceleration and Brake Potentiometer 258
Hydraulic System 260
Layout Drawing of Hydraulic System 260
CLSS 261
Structure of CLSS 261
Function of CLSS 262
Component Parts of Hydraulic System 265
Hydraulic Tank 265
Work Equipment and Cooling Fan Pump 267
LS Valve 272
PC Valve 278
LS-EPC Valve 282
Control Valve 285
Power Train System 302
Layout Drawing of HST System 302
Operation of HST System 303
Steering and Brake Control System 305
Layout Drawing of Steering and Brake Control System 305
Function of Steering and Brake Control System 305
HST Control System 307
System Diagram of HST Control System 307
Gear Shift Control Function 308
Engine Low Speed Matching Control Function 312
HST Pump and Motor Sequence Control Function 312
Deceleration and Brake Control Function 314
Gear Shift Control Function by Load 315
Turn Control Function 315
Straight Travel Correction Control Function 317
Parking Brake Control System 318
System Diagram of Parking Brake Control System (Applicable Machine: 70002 to 72160) 318
System Diagram of Parking Brake Control System (Applicable Machine: 72161 and Up) 319
Function of Parking Brake Control System 319
Operation of Parking Brake Control System 320
Component Parts of Power Train System 322
HST Pump 322
HST Charge Pump 336
HST Motor 344
Final Drive 357
Electric Steering Electric Lever 361
Work Equipment System 364
Work Equipment Control 364
Layout Drawing of Work Equipment Control 364
Function of Work Equipment Control 364
Layout Drawing of Front Work Equipment 366
Layout Drawing of Fixed Multi-Shank Ripper 367
Component Parts of Work Equipment System 368
5-Spool EPC and Solenoid Valve 369
Pilot Circuit Accumulator 375
Angle Control EPC Valve 376
Quick Drop Valve 379
Piston Valve 384
Electric Blade Control Lever 385
Ripper Electric Lever 387
Undercarriage and Frame 389
Main Frame 389
Structure of Main Frame 389
Suspension 390
Structure of Suspension 390
Specifications of Suspension 391
Function of Suspension 392
Track Frame and Idler Cushion 393
Structure of Track Frame and Idler Cushion 393
Function of Track Frame and Idler Cushion 395
Work Equipment 396
Structure of Front Work Equipment 396
Structure of Fixed Multi-Shank Ripper 397
CAB Related Parts 398
ROPS CAB 398
Structure of ROPS CAB 398
Function of ROPS CAB 399
CAB Mount 400
Structure of CAB Mount 400
Function of CAB Mount 400
20 Standard Value Table 401
Table of Contents 402
Standard Value Table for Engine 403
Standard Value Table for Engine: D71EX-24 403
Standard Value Table for Engine: D71EX-24E0 407
Standard Value Table for Engine: D71PX-24 411
Standard Value Table for Engine: D71PX-24E0 415
Standard Value Table for Machine 419
Standard Value Table for Machine: D71EX-24 419
Standard Value Table for Machine: D71EX-24E0 433
Standard Value Table for Machine: D71PX-24 447
Standard Value Table for Machine: D71PX-24E0 461
Machine Posture and Procedures to Measure Performance 475
30 Testing and Adjusting 477
Table of Contents 478
Precautions Before Work 481
Related Information on Testing and Adjusting 482
Differences In Machine Monitor Symbols 482
Tools for Testing and Adjusting 483
Sketch of Tools for Testing and Adjusting 491
Engine and Cooling System 493
Examine Engine Speed 493
How to Examine Engine Speed 493
Examine Boost Pressure 496
How to Examine Boost Pressure 496
Examine Exhaust Gas Temperature 498
How to Examine Exhaust Gas Temperature 498
Examine Exhaust Gas Color 501
How to Examine Exhaust Gas Color with the Handy Smoke Checker 501
How to Examine Exhaust Gas Color with Smoke Meter 503
Examine and Adjust Valve Clearance 505
How to Examine Valve Clearance 505
How to Adjust Valve Clearance 506
Examine Compression Pressure 508
How to Examine Compression Pressure 508
Examine Blowby Pressure 511
How to Examine Blowby Pressure 511
Examine Engine Oil Pressure 514
How to Examine Engine Oil Pressure 514
Examine EGR Valve and VGT Oil Pressure 516
How to Examine EGR Valve and VGT Oil Pressure 516
Examine Fuel Pressure 518
How to Examine Fuel Pressure 519
Examine Fuel Discharge, Return, and Leakage 527
How to Examine Fuel Discharge, Return, and Leakage 528
Bleed Air from Fuel System 533
How to Bleed Air from Fuel System 533
Examine Fuel Circuit for Leakage 536
How to Examine Fuel System for Leakage 536
Handle Cylinder Cut-out Mode Operation 538
Handle No-Injection Cranking Operation 539
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 540
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 540
Examine Installed Condition of Cylinder Heads and Manifolds 541
How to Examine Installed Condition of Cylinder Heads and Manifolds 541
Examine Engine Piping for Damage and Looseness 542
How to Examine Engine Piping for Damage and Looseness 542
Examine Alternator Belt 543
How to Examine Alternator Belt 543
Examine Automatic Tensioner 545
How to Examine Automatic Tensioner 545
Write Correction for Ash in Soot Accumulation to Engine Controller 547
How to Write Correction for Ash in Soot Accumulation to Engine Controller 547
Examine SCR Related Function 548
Examine DEF Pump Raised Pressure 552
Examine Injection Volume from DEF Injector 555
Examine DEF Line Heater Relay 1 560
Examine DEF Line Heater Relay 2 564
Examine DEF Pump Heater Relay 568
Examine DEF Tank Heater Valve 572
Examine SCR Denitration Efficiency 576
Clean DEF Tank 579
How to Clean DEF Tank 579
Clean DEF Tank Mounting Part 584
How to Clean DEF Tank Mounting Part 584
Clean DEF Pump 586
How to Clean DEF Pump 586
Power Train 592
Examine and Adjust HST Oil Pressure 592
How to Examine HST Oil Pressure 592
How to Adjust HST Oil Pressure 596
Bleed Air from HST Pump 599
How to Bleed Air from HST Pump 599
How to Bleed Air from Servo Valve of HST Pump 600
Examine Outlet Pressure of Solenoid Valve 602
How to Examine Outlet Pressure of Solenoid Valve 602
Examine Travel Deviation 609
How to Examine Travel Deviation 609
Examine Brake Performance Simply 611
How to Examine Brake Performance Simply 611
Examine and Adjust Deceleration/ Brake Pedal 612
How to Examine Deceleration/ Brake Pedal 612
How to Adjust Deceleration/ Brake Pedal 614
Move Machine When It Cannot Travel 616
How to Move Machine with Hydraulic Type Parking Brake Release System 616
How to Move Machine After You Remove Final Drive Shaft 619
Undercarriage and Frame 620
Examine and Adjust Idler Clearance 620
How to Adjust Idler Clearance 620
Examine Sprocket Wear 621
How to Examine Sprocket Wear 621
Examine and Adjust Track Tension 622
How to Examine Track Tension 622
How to Adjust Track Tension 622
Hydraulic System 623
Release Remained Pressure in Hydraulic Circuit 623
How to Release Remained Pressure in Hydraulic System 623
Examine and Adjust Work Equipment Circuit Oil Pressure 624
How to Examine Work Equipment Circuit Oil Pressure 624
How to Adjust Work Equipment Circuit Oil Pressure 626
Examine and Adjust Oil Pressure in Control Circuit 627
How to Examine Oil Pressure in Control Circuit 627
How to Adjust Oil Pressure in Control Circuit 629
Examine Outlet Pressure of EPC Solenoid Valve 630
How to Examine Outlet Pressure of EPC Solenoid Valve 630
Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 633
How to Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 633
Examine Cooling Fan Speed 635
How to Examine Cooling Fan Speed 635
Examine Cooling Fan Circuit Oil Pressure 636
How to Examine Cooling Fan Circuit Oil Pressure 636
Bleed Air in Cooling Fan Pump 638
How to Bleed Air in Cooling Fan Pump 638
Examine Parts Which Cause Hydraulic Drift of Work Equipment 639
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 639
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 639
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 640
Examine Oil Leakage from Work Equipment Cylinder 641
How to Examine Internal Oil Leakage of Work Equipment Cylinder 641
Bleed Air from Work Equipment Cylinders 644
How to Bleed Air from Work Equipment Cylinder 644
Work Equipment 645
Shim Adjustment of Center Ball 645
How to Adjust Shim of Center Ball 645
Examine and Adjust Play of Blade Electric Lever 646
How to Examine Play of Blade Electric Lever 648
How to Adjust Play of Blade Electric Lever 648
How to Replace Universal Joint 649
CAB Related Parts 656
Examine and Adjust Operator Cab 656
How to Examine Operator Cab 656
How to Adjust Operator Cab 658
Electrical System 661
Set and Operate Machine Monitor 661
Operator Mode 665
Function to Show Technician Identification Status Screen 665
Function to Show Operator Identification Input Screen 665
Examine Function by LCD (Liquid Crystal Display) 666
Examine Function of Service Meter 666
How to Set Usage Limitation and Change Maintenance Password 666
Service Mode 669
How to Operate Service Mode 669
How to See Pre-defined Monitoring Information 670
How to Examine Monitoring Information 684
Abnormality Record Menu 705
How to See Maintenance Record 709
Maintenance Mode Setting 710
How to Set Phone Number Entry 714
Default Setting Menu 715
Testing Menu 724
Adjustment Menu 733
No-Injection Cranking Operation 796
KOMTRAX Settings Menu 798
How to Show Service Message 800
How to Start Up KOMTRAX System 802
Adjust After Replacement of HST Controller 809
How to Adjust After Replacement of HST Controller 809
Adjust After Replacement of Electric and Hydraulic Equipment 814
Adjust Rearview Camera Angle 816
How to Adjust Rearview Camera Angle 816
Set Region of Bluetooth(R) Compatible Radio 817
How to Set Region of Bluetooth(R) Compatible Radio 817
Handle Voltage Circuit of Engine Controller 819
Handle Battery Disconnect Switch 820
Examine Diodes 821
How to Examine Diodes by Digital Tester 821
How to Examine Diodes by Analog Tester 821
Pm Clinic 822
Pm Clinic Service 822
Pm Clinic Check Sheet: D71EX-24 824
Pm Clinic Check Sheet: D71EX-24E0 832
Pm Clinic Check Sheet: D71PX-24 840
Pm Clinic Check Sheet: D71PX-24E0 847
Pm Clinic Check Sheet for Undercarriage: D71EX-24 854
Pm Clinic Check Sheet for Undercarriage: D71EX-24E0 862
Pm Clinic Check Sheet for Undercarriage: D71PX-24 870
Pm Clinic Check Sheet for Undercarriage: D71PX-24E0 878
40 Troubleshooting 887
Table of Contents 888
Precautions Before Work 900
Related Information to Troubleshooting 901
General Troubleshooting Points 901
Troubleshooting Points for Urea SCR System 902
Sequence of Events in Troubleshooting 916
Checks Before Troubleshooting 918
Inspection Procedure Before Troubleshooting 920
Walk-Around Check 920
Test in Accordance with Testing Procedure 922
Examine Fuel Level and Type 922
Examine for Impure Ingredient in Fuel 922
Examine DEF Level and Type 923
Examine Fuel Prefilter 923
Examine Fuel Main Filter 925
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 926
Examine Coolant Level (Expansion Tank) 927
Examine Air Cleaner Clogging 928
Clean Outer Element 929
Replace Element 931
Examine Hydraulic Oil Level 932
Examine Hydraulic Oil Strainer 933
Examine Hydraulic Oil Filter 936
Examine Oil Level in Final Drive Case 938
Bleed Air from Fuel System 938
Bleed Air from Hydraulic System 938
How to Examine Electric Equipment 938
How to Connect Adapter for Troubleshooting Controller 945
How to Connect Adapter for Troubleshooting Machine Monitor 945
How to Connect Adapter for Troubleshooting HST Controller 945
How to Connect Adapter for Troubleshooting Work Equipment Controller 946
How to Connect Adapter for Troubleshooting Gateway Function Controller 946
How to Connect Adapter for Troubleshooting Engine Controller 947
How to Connect Connectors for Engine Related Parts 948
Procedure for Troubleshooting 952
Information Shown in Troubleshooting Table 954
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 956
Connectors List 959
Connector Layout 969
Connector Contact Connection Table 979
T-Branch Box and T-Branch Adapter Table 1026
Fuse Location Table 1032
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1036
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1040
Failure Code Table 1042
Troubleshooting by Failure Code (Display of Code) 1064
Failure Code [6091NX] 1064
Failure Code [989L00] 1066
Failure Code [989M00] 1067
Failure Code [989N00] 1068
Failure Code [A1U0N3] 1069
Failure Code [A1U0N4] 1071
Failure Code [A900FR] 1073
Failure Code [A900N6] 1074
Failure Code [A900NY] 1075
Failure Code [AA10NX] 1076
Failure Code [AB00KE] 1078
Failure Code [AQ10N3] 1080
Failure Code [AS00N3] 1082
Failure Code [AS00R2] 1084
Failure Code [AS00R3] 1085
Failure Code [AS00R4] 1086
Failure Code [AS00R5] 1087
Failure Code [AS00R6] 1088
Failure Code [AS00ZK] 1089
Failure Code [AS10KM] 1090
Failure Code [AS10NR] 1091
Failure Code [AS10NT] 1092
Failure Code [B@BAZG] 1093
Failure Code [B@BCNS] 1094
Failure Code [B@BCQA] 1095
Failure Code [B@BCZK] 1097
Failure Code [B@CRNS] 1099
Failure Code [B@CRZG] 1100
Failure Code [CA115] 1101
Failure Code [CA122] 1102
Failure Code [CA123] 1105
Failure Code [CA131] 1108
Failure Code [CA132] 1110
Failure Code [CA144] 1112
Failure Code [CA145] 1115
Failure Code [CA153] 1117
Failure Code [CA154] 1120
Failure Code [CA187] 1123
Failure Code [CA221] 1125
Failure Code [CA222] 1127
Failure Code [CA227] 1129
Failure Code [CA234] 1130
Failure Code [CA238] 1131
Failure Code [CA239] 1133
Failure Code [CA249] 1135
Failure Code [CA256] 1137
Failure Code [CA271] 1139
Failure Code [CA272] 1141
Failure Code [CA281] 1143
Failure Code [CA322] 1144
Failure Code [CA323] 1146
Failure Code [CA324] 1148
Failure Code [CA325] 1150
Failure Code [CA331] 1152
Failure Code [CA332] 1154
Failure Code [CA343] 1156
Failure Code [CA351] 1157
Failure Code [CA352] 1158
Failure Code [CA356] 1161
Failure Code [CA357] 1163
Failure Code [CA386] 1165
Failure Code [CA428] 1166
Failure Code [CA429] 1168
Failure Code [CA435] 1170
Failure Code [CA441] 1172
Failure Code [CA442] 1175
Failure Code [CA449] 1176
Failure Code [CA451] 1180
Failure Code [CA452] 1183
Failure Code [CA515] 1185
Failure Code [CA516] 1187
Failure Code [CA553] 1189
Failure Code [CA555] 1190
Failure Code [CA556] 1191
Failure Code [CA559] 1192
Failure Code [CA595] 1196
Failure Code [CA687] 1197
Failure Code [CA689] 1199
Failure Code [CA691] 1204
Failure Code [CA692] 1206
Failure Code [CA697] 1208
Failure Code [CA698] 1209
Failure Code [CA731] 1210
Failure Code [CA778] 1212
Failure Code [CA1117] 1217
Failure Code [CA1664] 1218
Failure Code [CA1669] 1221
Failure Code [CA1673] 1222
Failure Code [CA1677] 1223
Failure Code [CA1678] 1224
Failure Code [CA1682] 1225
Failure Code [CA1683] 1230
Failure Code [CA1684] 1232
Failure Code [CA1686] 1234
Failure Code [CA1691] 1235
Failure Code [CA1694] 1238
Failure Code [CA1695] 1241
Failure Code [CA1696] 1242
Failure Code [CA1712] 1244
Failure Code [CA1713] 1247
Failure Code [CA1714] 1249
Failure Code [CA1715] 1250
Failure Code [CA1776] 1251
Failure Code [CA1777] 1254
Failure Code [CA1843] 1257
Failure Code [CA1844] 1259
Failure Code [CA1879] 1262
Failure Code [CA1881] 1264
Failure Code [CA1883] 1266
Failure Code [CA1885] 1270
Failure Code [CA1887] 1272
Failure Code [CA1921] 1274
Failure Code [CA1922] 1277
Failure Code [CA1942] 1282
Failure Code [CA1993] 1283
Failure Code [CA2185] 1286
Failure Code [CA2186] 1287
Failure Code [CA2249] 1289
Failure Code [CA2265] 1290
Failure Code [CA2266] 1292
Failure Code [CA2271] 1294
Failure Code [CA2272] 1297
Failure Code [CA2311] 1300
Failure Code [CA2349] 1301
Failure Code [CA2353] 1304
Failure Code [CA2357] 1306
Failure Code [CA2381] 1307
Failure Code [CA2382] 1310
Failure Code [CA2383] 1313
Failure Code [CA2386] 1316
Failure Code [CA2387] 1318
Failure Code [CA2555] 1319
Failure Code [CA2556] 1322
Failure Code [CA2637] 1325
Failure Code [CA2639] 1327
Failure Code [CA2771] 1330
Failure Code [CA2777] 1336
Failure Code [CA2976] 1339
Failure Code [CA3133] 1341
Failure Code [CA3134] 1343
Failure Code [CA3135] 1345
Failure Code [CA3142] 1349
Failure Code [CA3143] 1350
Failure Code [CA3144] 1351
Failure Code [CA3146] 1353
Failure Code [CA3147] 1354
Failure Code [CA3148] 1355
Failure Code [CA3151] 1357
Failure Code [CA3165] 1363
Failure Code [CA3229] 1365
Failure Code [CA3231] 1367
Failure Code [CA3232] 1369
Failure Code [CA3235] 1373
Failure Code [CA3239] 1375
Failure Code [CA3241] 1378
Failure Code [CA3242] 1381
Failure Code [CA3251] 1384
Failure Code [CA3253] 1386
Failure Code [CA3254] 1389
Failure Code [CA3255] 1392
Failure Code [CA3256] 1394
Failure Code [CA3311] 1396
Failure Code [CA3312] 1398
Failure Code [CA3313] 1401
Failure Code [CA3314] 1402
Failure Code [CA3315] 1403
Failure Code [CA3316] 1405
Failure Code [CA3317] 1406
Failure Code [CA3318] 1407
Failure Code [CA3319] 1409
Failure Code [CA3321] 1410
Failure Code [CA3322] 1412
Failure Code [CA3419] 1414
Failure Code [CA3421] 1416
Failure Code [CA3497] 1418
Failure Code [CA3498] 1419
Failure Code [CA3543] 1420
Failure Code [CA3545] 1425
Failure Code [CA3547] 1427
Failure Code [CA3558] 1428
Failure Code [CA3559] 1430
Failure Code [CA3562] 1432
Failure Code [CA3563] 1434
Failure Code [CA3567] 1437
Failure Code [CA3568] 1440
Failure Code [CA3571] 1446
Failure Code [CA3572] 1448
Failure Code [CA3574] 1450
Failure Code [CA3575] 1453
Failure Code [CA3577] 1455
Failure Code [CA3578] 1457
Failure Code [CA3582] 1459
Failure Code [CA3583] 1466
Failure Code [CA3596] 1468
Failure Code [CA3649] 1471
Failure Code [CA3681] 1473
Failure Code [CA3682] 1476
Failure Code [CA3713] 1478
Failure Code [CA3717] 1481
Failure Code [CA3718] 1482
Failure Code [CA3725] 1483
Failure Code [CA3741] 1486
Failure Code [CA3748] 1487
Failure Code [CA3751] 1489
Failure Code [CA3755] 1491
Failure Code [CA3866] 1493
Failure Code [CA3867] 1497
Failure Code [CA3868] 1500
Failure Code [CA3899] 1504
Failure Code [CA3911] 1506
Failure Code [CA3912] 1510
Failure Code [CA3932] 1512
Failure Code [CA3933] 1514
Failure Code [CA3934] 1516
Failure Code [CA3935] 1519
Failure Code [CA3936] 1521
Failure Code [CA4151] 1523
Failure Code [CA4152] 1527
Failure Code [CA4155] 1531
Failure Code [CA4156] 1534
Failure Code [CA4157] 1537
Failure Code [CA4158] 1539
Failure Code [CA4159] 1540
Failure Code [CA4161] 1541
Failure Code [CA4162] 1544
Failure Code [CA4163] 1547
Failure Code [CA4164] 1549
Failure Code [CA4165] 1551
Failure Code [CA4166] 1553
Failure Code [CA4168] 1555
Failure Code [CA4169] 1558
Failure Code [CA4171] 1560
Failure Code [CA4249] 1563
Failure Code [CA4251] 1565
Failure Code [CA4259] 1567
Failure Code [CA4261] 1570
Failure Code [CA4277] 1573
Failure Code [CA4281] 1577
Failure Code [CA4459] 1580
Failure Code [CA4461] 1583
Failure Code [CA4658] 1586
Failure Code [CA4731] 1590
Failure Code [CA4732] 1591
Failure Code [CA4739] 1592
Failure Code [CA4768] 1593
Failure Code [CA4769] 1595
Failure Code [CA4842] 1598
Failure Code [CA4952] 1602
Failure Code [CA5115] 1604
Failure Code [CA5179] 1607
Failure Code [CA5181] 1609
Failure Code [CA5383] 1611
Failure Code [D130KA] 1613
Failure Code [D130KB] 1616
Failure Code [D130KY] 1618
Failure Code [D19JKZ] 1620
Failure Code [D19UKA] 1623
Failure Code [D19UKB] 1625
Failure Code [D19UMC] 1627
Failure Code [D811MC] 1629
Failure Code [D862KA] 1630
Failure Code [D8ALKA] 1632
Failure Code [D8ALKB] 1634
Failure Code [D8AQKR] 1636
Failure Code [D8ARKR] 1638
Failure Code [D8G1KT] 1640
Failure Code [D8G6KT] 1641
Failure Code [DAF0MB] 1642
Failure Code [DAF0MC] 1643
Failure Code [DAF8KB] 1644
Failure Code [DAF9KQ] 1645
Failure Code [DAFGMC] 1646
Failure Code [DAFLKA] 1647
Failure Code [DAFLKB] 1649
Failure Code [DAFQKR] 1652
Failure Code [DAJ000] 1653
Failure Code [DAJ0KQ] 1654
Failure Code [DAJ0KT] 1655
Failure Code [DAJ0MC] 1656
Failure Code [DAJ1KK] 1657
Failure Code [DAJ2KK] 1659
Failure Code [DAJ2KT] 1661
Failure Code [DAJ5KK] 1662
Failure Code [DAJ6KK] 1665
Failure Code [DAJLKA] 1667
Failure Code [DAJLKB] 1669
Failure Code [DAJPMA] 1671
Failure Code [DAJQKR] 1672
Failure Code [DAJRKR] 1673
Failure Code [DB2QKR] 1674
Failure Code [DB2RKR] 1680
Failure Code [DB90KT] 1686
Failure Code [DB90MC] 1687
Failure Code [DB91KK] 1688
Failure Code [DB92KK] 1690
Failure Code [DB92KT] 1692
Failure Code [DB95KK] 1693
Failure Code [DB97KK] 1695
Failure Code [DB99KQ] 1697
Failure Code [DB9LKA] 1698
Failure Code [DB9LKB] 1700
Failure Code [DB9QKR] 1702
Failure Code [DB9RKR] 1703
Failure Code [DD12KA] 1704
Failure Code [DD12KB] 1706
Failure Code [DD13KA] 1708
Failure Code [DD13KB] 1710
Failure Code [DD14KA] 1712
Failure Code [DD14KB] 1715
Failure Code [DDE9KA] 1718
Failure Code [DDE9KB] 1720
Failure Code [DDKAKA] 1722
Failure Code [DDKAKB] 1724
Failure Code [DDKFL4] 1726
Failure Code [DDKGL4] 1728
Failure Code [DDKHKA] 1730
Failure Code [DDKHKB] 1732
Failure Code [DDNLKA] 1734
Failure Code [DDNLKB] 1737
Failure Code [DDP6KA] 1740
Failure Code [DDP6KB] 1743
Failure Code [DDP6MA] 1745
Failure Code [DDU1FS] 1747
Failure Code [DDU1KA] 1749
Failure Code [DDU1KY] 1752
Failure Code [DFA4KX] 1754
Failure Code [DFA4KZ] 1755
Failure Code [DFA4L8] 1756
Failure Code [DFA5KA] 1757
Failure Code [DFA5KB] 1759
Failure Code [DFA6KA] 1761
Failure Code [DFA6KB] 1763
Failure Code [DFA7KX] 1765
Failure Code [DFA7KZ] 1766
Failure Code [DFA7L8] 1767
Failure Code [DFA8KA] 1768
Failure Code [DFA8KB] 1771
Failure Code [DFA9KA] 1773
Failure Code [DFA9KB] 1776
Failure Code [DFAAKX] 1778
Failure Code [DFAAKZ] 1779
Failure Code [DFAAL8] 1780
Failure Code [DFABKA] 1781
Failure Code [DFABKY] 1784
Failure Code [DFACKA] 1786
Failure Code [DFACKY] 1789
Failure Code [DGS1KA] 1791
Failure Code [DGS1KX] 1794
Failure Code [DH21KA] 1795
Failure Code [DH21KB] 1797
Failure Code [DHA4KA] 1799
Failure Code [DHAAMA] 1801
Failure Code [DHACMA] 1803
Failure Code [DHH7KA] 1805
Failure Code [DHH7KB] 1807
Failure Code [DHH8KA] 1809
Failure Code [DHH8KB] 1811
Failure Code [DHH9KA] 1813
Failure Code [DHH9KB] 1815
Failure Code [DHHAKA] 1817
Failure Code [DHHAKB] 1820
Failure Code [DHZ1KX] 1822
Failure Code [DK30KA] 1824
Failure Code [DK30KB] 1827
Failure Code [DK30KX] 1829
Failure Code [DK30KZ] 1830
Failure Code [DK30L8] 1831
Failure Code [DK31KA] 1832
Failure Code [DK31KB] 1835
Failure Code [DK40KA] 1837
Failure Code [DK40KB] 1840
Failure Code [DK55KX] 1842
Failure Code [DK55KZ] 1843
Failure Code [DK55L8] 1844
Failure Code [DK56KA] 1845
Failure Code [DK56KB] 1848
Failure Code [DK57KA] 1850
Failure Code [DK57KB] 1853
Failure Code [DK80KR] 1855
Failure Code [DK80KT] 1858
Failure Code [DLM0KX] 1860
Failure Code [DLM1KA] 1861
Failure Code [DLM1KB] 1863
Failure Code [DLM1MA] 1865
Failure Code [DLM2KA] 1866
Failure Code [DLM2KB] 1868
Failure Code [DLM2MA] 1870
Failure Code [DLM3KA] 1871
Failure Code [DLM3KB] 1873
Failure Code [DLM3MB] 1875
Failure Code [DN21FS] 1876
Failure Code [DN21KA] 1878
Failure Code [DN21KY] 1881
Failure Code [DR21KX] 1883
Failure Code [DR31KX] 1884
Failure Code [DV20KB] 1885
Failure Code [DW4BKA] 1887
Failure Code [DW4BKB] 1889
Failure Code [DW4BKY] 1891
Failure Code [DW7BKA] 1893
Failure Code [DW7BKB] 1895
Failure Code [DW7EKA] 1897
Failure Code [DW7EKB] 1900
Failure Code [DW7EKY] 1903
Failure Code [DWH1KA] 1905
Failure Code [DWH1KB] 1907
Failure Code [DWN5KA] 1909
Failure Code [DWN5KB] 1911
Failure Code [DWN5KY] 1913
Failure Code [DXA4KA] (Applicable Machine: 70002 to 72160) 1915
Failure Code [DXA4KA] (Applicable Machine: 72161 and Up) 1917
Failure Code [DXA4KB] (Applicable Machine: 70002 to 72160) 1919
Failure Code [DXA4KB] (Applicable Machine: 72161 and Up) 1921
Failure Code [DXA4KY] (Applicable Machine: 70002 to 72160) 1923
Failure Code [DXA4KY] (Applicable Machine: 72161 and Up) 1925
Failure Code [DXA5KA] (Applicable Machine: 70002 to 72160) 1927
Failure Code [DXA5KA] (Applicable Machine: 72161 and Up) 1929
Failure Code [DXA5KB] (Applicable Machine: 70002 to 72160) 1931
Failure Code [DXA5KB] (Applicable Machine: 72161 and Up) 1933
Failure Code [DXA5KY] (Applicable Machine: 70002 to 72160) 1935
Failure Code [DXA5KY] (Applicable Machine: 72161 and Up) 1937
Failure Code [DXA6KA] (Applicable Machine: 70002 to 72160) 1939
Failure Code [DXA6KA] (Applicable Machine: 72161 and Up) 1941
Failure Code [DXA6KB] (Applicable Machine: 70002 to 72160) 1943
Failure Code [DXA6KB] (Applicable Machine: 72161 and Up) 1945
Failure Code [DXA6KY] (Applicable Machine: 70002 to 72160) 1947
Failure Code [DXA6KY] (Applicable Machine: 72161 and Up) 1949
Failure Code [DXA7KA] (Applicable Machine: 70002 to 72160) 1951
Failure Code [DXA7KA] (Applicable Machine: 72161 and Up) 1953
Failure Code [DXA7KB] (Applicable Machine: 70002 to 72160) 1955
Failure Code [DXA7KB] (Applicable Machine: 72161 and Up) 1957
Failure Code [DXA7KY] (Applicable Machine: 70002 to 72160) 1959
Failure Code [DXA7KY] (Applicable Machine: 72161 and Up) 1961
Failure Code [DXE0KA] 1963
Failure Code [DXE0KB] 1965
Failure Code [DXE0KY] 1966
Failure Code [DXHRKA] 1968
Failure Code [DXHRKB] 1970
Failure Code [DXHRKY] 1972
Failure Code [DXHSKA] 1974
Failure Code [DXHSKB] 1976
Failure Code [DXHSKY] 1978
Failure Code [DXHTKA] 1980
Failure Code [DXHTKB] 1982
Failure Code [DXHTKY] 1984
Failure Code [DXHUKA] 1986
Failure Code [DXHUKB] 1988
Failure Code [DXHUKY] 1990
Failure Code [DXHWKA] 1992
Failure Code [DXHWKB] 1994
Failure Code [DXHWKY] 1995
Failure Code [DXHXKA] 1997
Failure Code [DXHXKB] 1999
Failure Code [DXHXKY] 2000
Failure Code [DXJ4KA] 2002
Failure Code [DXJ4KB] 2004
Failure Code [DXJAKA] 2006
Failure Code [DXJAKB] 2008
Failure Code [DXJAKY] 2010
Failure Code [DXJCKA] 2012
Failure Code [DXJCKB] 2014
Failure Code [DXJCKY] 2016
Failure Code [DXJDKA] 2018
Failure Code [DXJDKB] 2020
Failure Code [DXJDKY] 2022
Failure Code [DXK1KA] 2024
Failure Code [DXK1KB] 2026
Failure Code [DXK1KY] 2028
Failure Code [DXK2KA] 2030
Failure Code [DXK2KB] 2032
Failure Code [DXK2KY] 2034
Failure Code [F311KA] 2036
Failure Code [F311KB] 2038
Failure Code [F312KA] 2040
Failure Code [F312KB] 2042
Failure Code [F313KA] 2044
Failure Code [F313KB] 2046
Failure Code [F314KA] 2049
Failure Code [F314KB] 2051
Failure Code [F315KB] 2053
Failure Code [F315KY] 2055
Failure Code [F316KB] 2057
Failure Code [F316KY] 2059
Failure Code [F318KB] 2061
Failure Code [F318KY] 2064
Failure Code [F31AKB] 2066
Failure Code [F31AKY] 2068
Failure Code [F31BKB] 2070
Failure Code [F31BKY] 2072
Failure Code [F31CKB] 2074
Failure Code [F31CKY] 2076
Failure Code [F31DKB] 2078
Failure Code [F31DKY] 2080
Failure Code [F31EKB] 2082
Failure Code [F31EKY] 2084
Failure Code [FS10ZE] 2086
Failure Code [M620KA] 2087
Failure Code [M620KB] 2089
Failure Code [M620KY] 2090
Troubleshooting of Electrical System (E-Mode) 2092
Engine Does Not Start (Engine Does Not Crank) 2092
Manual Preheating System Does Not Operate 2098
Automatic Preheating System Does Not Operate 2101
While Preheating is in Operation, Preheating Monitor Does Not Come On 2103
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2105
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 2108
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2109
Charge Level Monitor Comes On in Red While Engine is in Operation 2110
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 2111
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 2112
HST Charge Pressure Monitor Comes On in Red While Engine Runs 2113
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2114
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs 2115
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2116
DEF Level is Not Shown Correctly 2117
Fuel Gauge Does Not Show Normally 2120
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2123
Operation Mode Does Not Change 2124
When You Operate Customize Switch Does Not Show Customize Screen 2125
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 2126
Service Meter is Not Shown While Starting Switch is in OFF Position 2127
Service Mode Cannot be Selected 2128
Work Equipment Does Not Operate 2129
Foot Heater Does Not Operate 2131
Horn Does Not Sound 2137
Horn Does Not Stop 2139
Backup Alarm Does Not Sound 2140
Backup Alarm Does Not Stop Operation 2141
Headlamp Does Not Come On 2142
Rear Lamp Does Not Come On 2146
No Wiper Operates 2149
Front Wiper Does Not Operate 2151
Rear Wiper Does Not Operate 2155
Left Door Wiper Does Not Operate 2159
Right Door Wiper Does Not Operate 2163
Front Washer Does Not Operate 2167
Rear Washer Does Not Operate 2169
Left Door Washer Does Not Operate 2171
Right Door Washer Does Not Operate 2173
KOMTRAX System Does Not Operate Correctly 2175
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2176
Information Shown in Troubleshooting Table (H-Mode) 2176
Failure Mode and Cause Table 2177
R H and L H Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) 2183
R H or L H Track Cannot Travel FORWARD and REVERSE (One of R H or L H Travel Systems Cannot Operate) 2185
R H or L H Track Cannot Travel FORWARD or REVERSE (Only One of the Travel Systems Cannot Operate in One Direction) 2187
Travel Speed or Power is Low 2189
Speed Range Does Not Change 2191
Shock is Large When Machine Moves Off or Stops 2192
Travel Deviation is Large 2193
Machine Drift on a Slope is Large 2196
Engine Speed Drops Largely or Engine Stops 2198
Unusual Noise is Heard from Around HST Pump or Motor 2200
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 2202
All Work Equipment Speed or Power is Low 2204
Blade Lift Speed or Power is Low 2205
Blade Tilt Speed or Power is Low 2207
Blade Angle Speed or Power is Low 2208
Hydraulic Drift of Lifted Ripper is Large 2210
Time Lag of Blade Lift is Large 2211
Hydraulic Drift of Blade Lift is Large 2212
Hydraulic Drift of Tilted Blade is Large 2213
Hydraulic Drift of Lifted Ripper is Large 2214
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 2215
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2216
Unusual Noise is Heard from Around Fan 2218
Troubleshooting of Engine (S-Mode) 2219
Information Shown in Troubleshooting Table (S-Mode) 2219
Engine Does Not Crank When Starting Switch is Turned to Start Position 2220
Engine Cranks but No Exhaust Smoke Comes Out 2221
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2222
Engine Startability is Unsatisfactory 2224
Engine Does Not Pick Up Smoothly 2226
Engine Stops During Operation 2228
Engine Does Not Rotate Smoothly 2230
Engine Lacks Output (or Lacks Power) 2231
KDPF Becomes Clogged in a Short Time 2233
Engine Oil Consumption is Excessive 2235
Engine Oil Becomes Dirty Quickly 2236
Fuel Consumption is Excessive 2237
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2238
Engine Oil Pressure Drops 2239
Fuel Mixes Into Engine Oil 2241
Water Mixes Into Engine Oil (Milky) 2242
Coolant Temperature Increases Too High (Overheat) 2243
Unusual Noise is Heard 2244
Vibration is Excessive 2245
Air Cannot be Bled from Fuel Circuit 2246
Active Regeneration is Done Frequently 2247
Active Regeneration Continues Long 2249
White Smoke is Exhausted During Active Regeneration 2250
DEF Consumption is Excessive 2251
There is an Unusual Smell (Irritating Odor) 2253
Foreign Materials Enter DEF (DEF Increases) 2254
50 Disassembly and Assembly 2255
Table of Contents 2256
Precautions Before Work 2262
Related Information on Disassembly and Assembly 2263
How to Read This Manual 2263
Coating Materials List 2264
Special Tool List 2269
Sketches of Special Tools 2289
Prepare 2301
Drain and Add Coolant 2301
How to Drain Coolant 2302
How to Add Coolant 2303
Drain and Add Hydraulic Oil 2306
How to Drain Hydraulic Oil 2307
How to Add Hydraulic Oil 2307
Drain and Add Fuel 2309
How to Drain Fuel 2309
How to Add Fuel 2310
Collect and Refill Refrigerant 2311
How to Collect Refrigerant 2312
How to Refill Refrigerant 2312
Engine and Cooling System 2313
Remove and Install Supply Pump Assembly 2313
How to Remove Supply Pump Assembly 2314
How to Install Supply Pump Assembly 2317
Remove and Install Injector Assembly 2322
How to Remove Injector Assembly 2323
How to Install Injector Assembly 2333
Remove and Install Cylinder Head Assembly 2348
How to Remove Cylinder Head Assembly 2350
How to Install Cylinder Head Assembly 2364
Remove and Install EGR Valve Assembly 2385
How to Remove EGR Valve Assembly 2386
How to Install EGR Valve Assembly 2387
Remove and Install EGR Cooler Assembly 2388
How to Remove EGR Cooler Assembly 2389
How to Install EGR Cooler Assembly 2390
Remove and Install Starter Assembly 2393
How to Remove Starting Motor Assembly 2394
How to Install Starting Motor Assembly 2396
Remove and Install Alternator Belt 2399
How to Remove Alternator Belt 2400
How to Install Alternator Belt 2401
Remove and Install Automatic Tensioner 2403
How to Remove Auto-Tensioner 2403
How to Install Auto-Tensioner 2404
Remove and Install Radiator Assembly 2405
How to Remove Radiator Assembly 2406
How to Install Radiator Assembly 2411
Remove and Install Hydraulic Oil Cooler Assembly 2416
How to Remove Hydraulic Oil Cooler Assembly 2417
How to Install Hydraulic Oil Cooler Assembly 2421
Remove and Install Aftercooler Assembly 2425
How to Remove Aftercooler Assembly 2426
How to Install Aftercooler Assembly 2429
Remove and Install Cooling Fan Drive Assembly 2433
How to Remove Cooling Fan Drive Assembly 2434
How to Install Cooling Fan Drive Assembly 2438
Remove and Install Cooling Fan Motor Assembly 2443
How to Remove Cooling Fan Motor Assembly 2444
How to Install Cooling Fan Motor Assembly 2447
Remove and Install Engine and HST Pump Assembly 2450
How to Remove Engine and HST Pump Assembly 2452
How to Install Engine and HST Pump Assembly 2466
Remove and Install Engine Front Oil Seal 2482
How to Remove Engine Front Oil Seal 2483
How to Install Engine Front Oil Seal 2488
Remove and Install Engine Rear Oil Seal 2493
How to Remove Engine Rear Oil Seal 2494
How to Install Engine Rear Oil Seal 2496
Remove and Install Engine Hood Assembly 2503
How to Remove Engine Hood Assembly 2504
How to Install Engine Hood Assembly 2511
Remove and Install Fuel Tank Assembly 2518
How to Remove Fuel Tank Assembly 2520
How to Install Fuel Tank Assembly 2528
Remove and Install DEF Tank Assembly 2535
How to Remove DEF Tank Assembly 2536
How to Install DEF Tank Assembly 2541
Remove and Install DEF Tank Sensor Flange Assembly 2546
How to Remove DEF Tank Sensor Flange Assembly 2547
How to Install DEF Tank Sensor Flange Assembly 2548
Remove and Install DEF Tank Sensor 2551
How to Remove DEF Tank Sensor 2552
How to Install DEF Tank Sensor 2553
Remove and Install DEF Tank Strainer 2560
How to Remove DEF Tank Strainer 2560
How to Install DEF Tank Strainer 2561
Remove and Install KDPF Assembly 2562
How to Remove KDPF Assembly 2563
How to Install KDPF Assembly 2567
Disassemble and Assemble KDPF Assembly 2573
How to Disassemble KDPF Assembly 2574
How to Assemble KDPF Assembly 2579
Remove and Install SCR Assembly 2586
How to Remove SCR Assembly 2587
How to Install SCR Assembly 2589
Remove and Install KDPF and SCR Assembly 2591
How to Remove KDPF and SCR Assembly 2592
How to Install KDPF and SCR Assembly 2603
Remove and Install KCCV Assembly 2615
How to Remove KCCV Assembly 2616
How to Install KCCV Assembly 2618
Remove and Install VGT Assembly 2620
How to Remove VGT Assembly 2621
How to Install VGT Assembly 2623
Remove and Install DEF Mixing Tube 2627
How to Remove DEF Mixing Tube 2628
How to Install DEF Mixing Tube 2632
Remove and Install DEF Injector 2638
How to Remove DEF Injector 2639
How to Install DEF Injector 2642
Remove and Install DEF Pump 2645
How to Remove DEF Pump 2646
How to Install DEF Pump 2650
Remove and Install DEF Hose 2653
How to Remove DEF Hose 2654
How to Install DEF Hose 2664
Remove and Install Air Cleaner Assembly 2673
How to Remove Air Cleaner Assembly 2674
How to Install Air Cleaner Assembly 2676
Remove and Install Air Conditioner Compressor Assembly 2678
How to Remove Air Conditioner Compressor Assembly 2679
How to Install Air Conditioner Compressor Assembly 2681
Remove and Install Air Conditioner Condenser Assembly 2683
How to Remove Air Conditioner Condenser Assembly 2684
How to Install Air Conditioner Condenser Assembly 2688
Power Train 2692
Remove and Install Damper Assembly 2692
How to Remove Damper Assembly 2692
How to Install Damper Assembly 2693
Remove and Install HST Pump Assembly 2694
How to Remove HST Pump Assembly 2695
How to Install HST Pump Assembly 2701
Remove and Install HST Motor and Final Drive Assembly 2708
How to Remove HST Motor and Final Drive Assembly 2709
How to Install HST Motor and Final Drive Assembly 2716
Disassemble and Assemble Final Drive Assembly 2723
How to Disassemble Final Drive Assembly 2724
How to Assemble Final Drive Assembly 2730
Undercarriage and Frame 2739
Remove and Install Track Frame Assembly 2739
How to Remove Track Frame Assembly 2740
How to Install Track Frame Assembly 2755
Remove and Install Idler Assembly 2768
How to Remove Idler Assembly 2769
How to Install Idler Assembly 2772
Disassemble and Assemble Idler Assembly 2775
How to Disassemble Idler Assembly 2775
How to Assemble Idler Assembly 2777
Remove and Install Recoil Spring Assembly 2782
How to Remove Recoil Spring Assembly 2782
How to Install Recoil Spring Assembly 2783
Disassemble and Assemble Recoil Spring Assembly 2784
How to Disassemble Recoil Spring Assembly 2784
How to Assemble Recoil Spring Assembly 2787
Remove and Install Track Roller Assembly 2790
How to Remove Track Roller Assembly 2791
How to Install Track Roller Assembly 2793
Disassemble and Assemble Track Roller Assembly 2796
How to Disassemble Track Roller Assembly 2796
How to Assemble Track Roller Assembly 2798
Remove and Install Carrier Roller Assembly 2802
How to Remove Carrier Roller Assembly 2803
How to Install Carrier Roller Assembly 2804
Disassemble and Assemble Carrier Roller Assembly 2806
How to Disassemble Carrier Roller Assembly 2806
How to Assemble Carrier Roller Assembly 2807
Remove and Install Pivot Shaft Assembly 2810
How to Remove Pivot Shaft Assembly 2811
How to Install Pivot Shaft Assembly 2812
Separate and Connect Track Assembly 2815
How to Examine Before Separation of Track Assembly 2816
How to Separate Track Assembly (Standard) 2816
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2817
How to Install Track Assembly 2818
Disassemble and Assemble Track Assembly Generally 2821
How to Disassemble Full Track Shoe Assembly 2821
How to Assemble Full Track Shoe Assembly 2826
Disassemble and Assemble PLUS Type Track Assembly Generally 2840
Disassemble PLUS Type Track Assembly Generally 2841
How to Assemble PLUS Type Track Shoe Assembly Generally 2842
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2857
How to Disassemble One Track Link Assembly in Field (Track Assembly) 2858
How to Assemble One Track Link Assembly in Field (Track Assembly) 2859
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2866
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2867
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2869
Remove and Install Equalizer Bar Assembly 2873
How to Remove Equalizer Bar Assembly 2874
How to Install Equalizer Bar Assembly 2876
Disassemble and Assemble Equalizer Bar Bushing 2879
How to Disassemble Equalizer Bar Bushing 2880
How to Assemble Equalizer Bar Bushing 2881
Remove and Install Segment Teeth 2882
How to Remove Segment Teeth 2883
How to Install Segment Teeth 2884
Hydraulic System 2886
Remove and Install Hydraulic Tank Assembly 2886
How to Remove Hydraulic Tank Assembly 2887
How to Install Hydraulic Tank Assembly 2893
Remove and Install Control Valve Assembly 2900
How to Remove Control Valve Assembly 2902
How to Install Control Valve Assembly 2908
Work Equipment 2915
Remove and Install Ripper Assembly 2915
How to Remove Ripper Assembly 2917
How to Install Ripper Assembly 2929
Remove and Install Blade Assembly 2941
How to Remove Blade Assembly 2942
How to Install Blade Assembly 2946
Remove and Install Work Equipment Assembly 2950
How to Remove Work Equipment Assembly 2951
How to Install Work Equipment Assembly 2955
Disassemble and Assemble Blade Lift Cylinder Assembly 2959
How to Disassemble Blade Lift Cylinder Assembly 2959
How to Assemble Blade Lift Cylinder Assembly 2961
Disassemble and Assemble Blade Angle Cylinder Assembly 2964
How to Disassemble Blade Angle Cylinder Assembly 2964
How to Assemble Blade Angle Cylinder Assembly 2966
Disassemble and Assemble Blade Tilt Cylinder Assembly 2970
How to Disassemble Blade Tilt Cylinder Assembly 2970
How to Assemble Blade Tilt Cylinder Assembly 2972
Disassemble and Assemble Ripper Lift Cylinder Assembly 2975
How to Disassemble Ripper Lift Cylinder Assembly 2975
How to Assemble Ripper Lift Cylinder Assembly 2977
CAB Related Parts 2980
Remove and Install Operator Cab Assembly 2980
How to Remove Operator Cab Assembly 2981
How to Install Operator Cab Assembly 2991
Remove and Install Operator Cab Glass (Adhered Glass) 3001
How to Remove Operator Cab Glass (Adhered Glass) 3003
How to Install Operator Cab Glass (Adhered Glass) 3003
Remove and Install Air Conditioner Unit Assembly 3009
How to Remove Air Conditioner Unit Assembly 3010
How to Install Air Conditioner Unit Assembly 3015
Remove and Install Receiver Drier 3021
How to Remove Receiver Drier 3022
How to Install Receiver Drier 3023
Remove and Install Operator Seat 3025
How to Remove Operator Seat 3026
How to Install Operator Seat 3028
How to Remove and Install Seat Belt 3030
How to Remove Seat Belt 3031
How to Install Seatbelt 3032
Remove and Install Foot Heater Assembly 3033
How to Remove Foot Heater Assembly 3034
How to Install Foot Heater Assembly 3037
Disassemble and Assemble Foot Heater Assembly 3041
How to Disassemble Foot Heater Assembly 3042
How to Assemble Foot Heater Assembly 3043
Electrical System 3046
Remove and Install Engine Controller Assembly 3046
How to Remove Engine Controller Assembly 3047
How to Install Engine Controller Assembly 3049
Remove and Install HST Controller Assembly 3052
How to Remove HST Controller Assembly 3053
How to Install HST Controller Assembly 3053
Remove and Install Work Equipment Controller Assembly 3055
How to Remove Work Equipment Controller Assembly 3056
How to Install Work Equipment Controller Assembly 3056
Remove and Install Machine Monitor Assembly 3058
How to Remove Machine Monitor Assembly 3059
How to Install Machine Monitor Assembly 3060
Remove and Install Mass Air Flow and Temperature Sensor 3062
How to Remove Mass Air Flow and Temperature Sensor 3063
How to Install Mass Air Flow and Temperature Sensor 3064
Remove and Install KCCV Crankcase Pressure Sensor 3065
How to Remove KCCV Crankcase Pressure Sensor 3066
How to Install KCCV Crankcase Pressure Sensor 3066
Remove and Install KDPF Temperature Sensor 3068
How to Remove KDPF Temperature Sensor 3069
How to Install KDPF Temperature Sensor 3071
Remove and Install KDPF Differential Pressure Sensor 3075
How to Remove KDPF Differential Pressure Sensor 3076
How to Install KDPF Differential Pressure Sensor 3077
Remove and Install SCR Temperature Sensor 3080
How to Remove SCR Temperature Sensor 3081
How to Install SCR Temperature Sensor 3083
Remove and Install Ammonia Sensor 3085
How to Remove Ammonia Sensor 3086
How to Install Ammonia Sensor 3087
Remove and Install SCR Outlet NOx Sensor 3089
How to Remove SCR Outlet NOx Sensor 3090
How to Install SCR Outlet NOx Sensor 3092
Remove and Install Rearview Camera 3095
How to Remove Rearview Camera 3096
How to Install Rearview Camera 3097
Remove and Install Gateway Function Controller 3098
How to Remove Gateway Function Controller 3099
How to Install Gateway Function Controller 3100
Remove and Install IMU Sensor 3102
How to Remove IMU Sensor 3103
How to Install IMU Sensor 3104
60 Maintenance Standard 3105
Table of Contents 3106
Explanation of Terms for Maintenance Standard 3107
Engine and Cooling System 3109
Maintenance Standard for Engine Mount 3109
Maintenance Standard for Damper 3110
Maintenance Standard for Cooling System 3111
Maintenance Standard for Cooling Fan Motor 3112
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 3114
Power Train 3115
Maintenance Standard for HST Pump 3115
Maintenance Standard for EPC Valve of HST Pump 3116
Maintenance Standard for Tow Receiving Valve of HST Pump 3117
Maintenance Standard for HST Charge Pump 3118
Maintenance Standard for Servo Valve 3120
Maintenance Standard for HST Motor 3122
Maintenance Standard for Final Drive 3123
Maintenance Standard for Sprocket for Conventional Type Track Shoes 3125
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 3126
Maintenance Standard for Sprocket for PLUS Type Track Shoes 3128
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3129
Undercarriage and Frame 3131
Maintenance Standard for Suspension 3131
Maintenance Standard for Track Frame and Idler Cushion 3134
Maintenance Standard for Idler 3136
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 3138
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 3139
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 3140
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 3141
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 3142
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 3143
Maintenance Standard for Conventional Type Track Shoes 3144
Maintenance Standard for PLUS Type Track Shoes 3146
Maintenance Standard for Single Shoes 3148
Maintenance Standard for Swamp Shoes 3149
Hydraulic System 3150
Maintenance Standard for Hydraulic Tank 3150
Maintenance Standard for Work Equipment and Cooling Fan Pump 3151
Maintenance Standard for LS-EPC Valve 3152
Maintenance Standard for Control Valve 3153
Maintenance Standard for 5-Spool EPC and Solenoid Valve 3161
Maintenance Standard for EPC Valve 3162
Maintenance Standard for Angle Control EPC Valve 3163
Maintenance Standard for Quick Drop Valve 3164
Work Equipment 3166
Maintenance Standard for Front Work Equipment 3166
Maintenance Standard for Cutting Edge and End Bit 3169
Maintenance Standard for Blade Lift Cylinder 3170
Maintenance Standard for Blade Tilt Cylinder 3171
Maintenance Standard for Blade Angle Cylinder 3172
Maintenance Standard for Fixed Multi-Shank Ripper 3173
Maintenance Standard for Ripper Lift Cylinder 3175
CAB Related Parts 3176
Maintenance Standard for CAB Mount 3176
Electrical System 3177
Maintenance Standard for Steering Electric Lever 3177
80 Appendix 3179
Table of Contents 3180
Precautions Before Work 3181
Air Conditioner System 3182
Precautions for Refrigerant 3182
Air Conditioner Component 3183
Specifications of Air Conditioner 3186
Structure and Function of Refrigeration Cycle 3187
Outline of Refrigeration Cycle 3188
Component Parts of Air Conditioner System 3190
Air Conditioner Unit 3190
Configuration Diagram of Air Conditioner Unit 3190
Function of Air Conditioner Unit 3191
Component Parts of Air Conditioner Unit 3192
Function of Evaporator as Air Conditioner Unit Component 3192
Function of Heater Core as Air Conditioner Unit Component 3192
Function of Thermostat as Air Conditioner Unit Component 3192
Structure of Expansion Valve as Air Conditioner Unit Component 3193
Function of Expansion Valve as Air Conditioner Unit Component 3193
Operate Expansion Valve as Air Conditioner Unit Component 3193
Function of Dual Pressure Switch 3194
Function of Pressure Switch 3194
Compressor 3195
Structure of Compressor 3195
Specifications of Compressor 3195
Function of Compressor 3195
Condenser 3196
Structure of Condenser 3196
Specifications of Condenser 3196
Function of Condenser 3197
Receiver Drier 3198
Structure of Receiver Dryer 3198
Specifications of Receiver Dryer 3198
Function of Receiver Dryer 3198
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3200
Circuit Diagram of Air Conditioner 3203
System Diagram of Air Conditioner 3204
Control Function of Air Conditioner 3205
Locations of Air Conditioner Parts and Layout of Connectors 3206
Examine Relay 3210
How to Examine Relay 3210
Air Conditioner Troubleshooting Chart 1 3212
Air Conditioner Troubleshooting Chart 2 3213
Information Shown in Troubleshooting Table 3216
Troubleshooting for Condenser Fan 3217
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3220
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3224
Troubleshooting for Temperature Control Function 3227
Troubleshooting by Gauge Pressure 3231
Connect Service Tool 3233
How to Connect Service Tool 3233
Precautions for Disconnection and Connection of Air Conditioner Piping 3234
Handle Compressor Oil 3236
90 Circuit Diagrams 3239
Table of Contents 3240
How to Read the Codes for Electric Cable 3242
Hydraulic Circuit Diagram 3246
Symbols Used in Hydraulic Circuit Diagram 3246
Hydraulic Circuit Diagram 3251
Hydraulic Circuit Diagram (Combination of Forward, Blade LOWER, and Cooling Fan Turns Normally) 3253
Hydraulic Circuit Diagram (Combination of Blade RAISE, Reverse, and Cooling Fan Turns Normally) 3255
Electrical Circuit Diagram 3257
Symbols Used in Electric Circuit Diagram 3257
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (1/16) 3261
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (2/16) 3263
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (3/16) 3265
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (4/16) 3267
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (5/16) 3269
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (6/16) 3271
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (7/16) 3273
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (8/16) 3275
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (9/16) 3277
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (10/16) 3279
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (11/16) 3281
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (12/16) 3283
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (13/16) 3285
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (14/16) 3287
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (15/16) 3289
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (16/16) 3291
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (1/17) 3293
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (2/17) 3295
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (3/17) 3297
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (4/17) 3299
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (5/17) 3301
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (6/17) 3303
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (7/17) 3305
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (8/17) 3307
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (9/17) 3309
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (10/17) 3311
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (11/17) 3313
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (12/17) 3315
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (13/17) 3317
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (14/17) 3319
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (15/17) 3321
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (16/17) 3323
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (17/17) 3325
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (1/18) 3327
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (2/18) 3329
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (3/18) 3331
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (4/18) 3333
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (5/18) 3335
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (6/18) 3337
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (7/18) 3339
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (8/18) 3341
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (9/18) 3343
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (10/18) 3345
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (11/18) 3347
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (12/18) 3349
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (13/18) 3351
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (14/18) 3353
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (15/18) 3355
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (16/18) 3357
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (17/18) 3359
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (18/18) 3361
Index 3363Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 23
How to Read the Shop Manual 23
Safety Notice for Operation 25
Precautions to Prevent Fire 33
Procedures If Fire Occurs 35
Precautions for Disposing of Waste Materials 36
Procedures for Exhaust Gas Regulations 37
Precautions for DEF 38
General Character and Precautions for Handling 38
Precautions for Adding 38
Precautions for Storage 38
Precautions for Fire Hazard and Leakage 38
Other Precautions 38
Store DEF 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment 52
Precautions When You Handle Intake System Equipment 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 57
Precautions for Disconnection and Connection of Connectors 59
How to Disconnect and Connect Deutsch Connector 63
How to Disconnect and Connect Slide Lock Type Connector 64
How to Disconnect and Connect Connector with Lock to Pull 66
How to Disconnect and Connect Connector with Lock to Push 67
How to Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard 74
Standard Tightening Torque Table 77
Conversion Table 84
Abbreviation List 89
01 Specifications 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: D71EX-24, D71EX-24E0 95
Specification Drawing: D71PX-24, D71PX-24E0 97
Specification Drawing: D71PX-24, D71PX-24E0 (Wide Gauge Specification) 99
Specifications 101
Specifications: D71EX-24, D71EX-24E0 101
Specifications: D71PX-24, D71PX-24E0 106
Specifications: D71PX-24, D71PX-24E0 (Wide Gauge Specification) 111
Weight Table 116
Weight Table: D71EX-24, D71EX-24E0 116
Weight Table: D71PX-24, D71PX-24E0 118
Weight Table: D71PX-24, D71PX-24E0 (Wide Gauge Specification) 120
Fuel, Coolant, Lubricants (For North America) 122
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 122
Fuel, Coolant, Lubricants (For European Union) 124
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 124
10 Structure and Function 127
Table of Contents 128
Urea SCR System 131
Layout Drawing of Urea SCR System 131
Urea SCR System Diagram 133
Function of Urea SCR System 134
Function of DEF System (Applicable Machine: 70002 to 70281) 134
Function of DEF System (Applicable Machine: 70282 and Up) 136
Inducement Strategy 138
Component Parts of Urea SCR System 152
DEF Mixing Tube 152
SCR Assembly 153
DEF Tank 155
DEF Pump 157
DEF Injector 158
DEF Hose 159
DEF Tank Heating Valve 160
Boot-up System 161
Layout Drawing of Boot-up System 161
System Operating Lamp System 162
System Diagram of System Operating Lamp System 162
Function of System Operating Lamp System (Applicable Machine: 70002 to 70281) 162
Function of System Operating Lamp System (Applicable Machine: 70282 and Up) 163
Battery Disconnect Switch 165
Function of Battery Disconnect Switch (Applicable Machine: 70002 to 70281) 165
Function of Battery Disconnect Switch (Applicable Machine: 70282 and Up) 165
Operation of Battery Disconnect Switch 165
Assistance Valve for Startup 167
Structure of Assistance Valve for Startup 167
Function of Assistance Valve for Startup 167
Engine System 168
Layout Drawing of Engine System 168
Engine Control System 170
Layout Drawing of Engine Control System 170
System Diagram of Engine Control 172
Function of Engine Control System 173
Engine Automatic Warm-up System 175
Function of Engine Automatic Warm-up System 175
Automatic Idle Stop System 176
System Diagram of Automatic Idle Stop System 176
Function of Automatic Idle Stop System 176
Component Parts of Engine System 179
Damper 179
VGT 180
EGR System 184
EGR Valve 186
EGR Cooler 188
KCCV System 190
KCCV Ventilator 192
KDPF 194
Cooling System 198
Layout Drawing of Cooling System 198
Specifications of Cooling System 199
Cooling Fan Control System 200
System Diagram of Cooling Fan Control System 200
Function of Cooling Fan Control System 200
Component Parts of Cooling System 202
Cooling Fan Motor 202
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 208
Hydraulic Oil Cooler Bypass Valve 210
HST Charge Safety Valve 211
Control System 213
Layout Drawing of Control System 213
Machine Monitor System 214
System Diagram of Machine Monitor System 214
Function of Machine Monitor System 214
KOMTRAX System 216
System Diagram of KOMTRAX System 216
Function of KOMTRAX System 216
Component Parts of Control System 217
Machine Monitor 217
Gateway Function Controller 236
Communication Terminal 239
HST Controller 241
Work Equipment Controller 245
Engine Controller 249
Fuel Control Dial 256
Deceleration and Brake Potentiometer 258
Hydraulic System 260
Layout Drawing of Hydraulic System 260
CLSS 261
Structure of CLSS 261
Function of CLSS 262
Component Parts of Hydraulic System 265
Hydraulic Tank 265
Work Equipment and Cooling Fan Pump 267
LS Valve 272
PC Valve 278
LS-EPC Valve 282
Control Valve 285
Power Train System 302
Layout Drawing of HST System 302
Operation of HST System 303
Steering and Brake Control System 305
Layout Drawing of Steering and Brake Control System 305
Function of Steering and Brake Control System 305
HST Control System 307
System Diagram of HST Control System 307
Gear Shift Control Function 308
Engine Low Speed Matching Control Function 312
HST Pump and Motor Sequence Control Function 312
Deceleration and Brake Control Function 314
Gear Shift Control Function by Load 315
Turn Control Function 315
Straight Travel Correction Control Function 317
Parking Brake Control System 318
System Diagram of Parking Brake Control System (Applicable Machine: 70002 to 72160) 318
System Diagram of Parking Brake Control System (Applicable Machine: 72161 and Up) 319
Function of Parking Brake Control System 319
Operation of Parking Brake Control System 320
Component Parts of Power Train System 322
HST Pump 322
HST Charge Pump 336
HST Motor 344
Final Drive 357
Electric Steering Electric Lever 361
Work Equipment System 364
Work Equipment Control 364
Layout Drawing of Work Equipment Control 364
Function of Work Equipment Control 364
Layout Drawing of Front Work Equipment 366
Layout Drawing of Fixed Multi-Shank Ripper 367
Component Parts of Work Equipment System 368
5-Spool EPC and Solenoid Valve 369
Pilot Circuit Accumulator 375
Angle Control EPC Valve 376
Quick Drop Valve 379
Piston Valve 384
Electric Blade Control Lever 385
Ripper Electric Lever 387
Undercarriage and Frame 389
Main Frame 389
Structure of Main Frame 389
Suspension 390
Structure of Suspension 390
Specifications of Suspension 391
Function of Suspension 392
Track Frame and Idler Cushion 393
Structure of Track Frame and Idler Cushion 393
Function of Track Frame and Idler Cushion 395
Work Equipment 396
Structure of Front Work Equipment 396
Structure of Fixed Multi-Shank Ripper 397
CAB Related Parts 398
ROPS CAB 398
Structure of ROPS CAB 398
Function of ROPS CAB 399
CAB Mount 400
Structure of CAB Mount 400
Function of CAB Mount 400
20 Standard Value Table 401
Table of Contents 402
Standard Value Table for Engine 403
Standard Value Table for Engine: D71EX-24 403
Standard Value Table for Engine: D71EX-24E0 407
Standard Value Table for Engine: D71PX-24 411
Standard Value Table for Engine: D71PX-24E0 415
Standard Value Table for Machine 419
Standard Value Table for Machine: D71EX-24 419
Standard Value Table for Machine: D71EX-24E0 433
Standard Value Table for Machine: D71PX-24 447
Standard Value Table for Machine: D71PX-24E0 461
Machine Posture and Procedures to Measure Performance 475
30 Testing and Adjusting 477
Table of Contents 478
Precautions Before Work 481
Related Information on Testing and Adjusting 482
Differences In Machine Monitor Symbols 482
Tools for Testing and Adjusting 483
Sketch of Tools for Testing and Adjusting 491
Engine and Cooling System 493
Examine Engine Speed 493
How to Examine Engine Speed 493
Examine Boost Pressure 496
How to Examine Boost Pressure 496
Examine Exhaust Gas Temperature 498
How to Examine Exhaust Gas Temperature 498
Examine Exhaust Gas Color 501
How to Examine Exhaust Gas Color with the Handy Smoke Checker 501
How to Examine Exhaust Gas Color with Smoke Meter 503
Examine and Adjust Valve Clearance 505
How to Examine Valve Clearance 505
How to Adjust Valve Clearance 506
Examine Compression Pressure 508
How to Examine Compression Pressure 508
Examine Blowby Pressure 511
How to Examine Blowby Pressure 511
Examine Engine Oil Pressure 514
How to Examine Engine Oil Pressure 514
Examine EGR Valve and VGT Oil Pressure 516
How to Examine EGR Valve and VGT Oil Pressure 516
Examine Fuel Pressure 518
How to Examine Fuel Pressure 519
Examine Fuel Discharge, Return, and Leakage 527
How to Examine Fuel Discharge, Return, and Leakage 528
Bleed Air from Fuel System 533
How to Bleed Air from Fuel System 533
Examine Fuel Circuit for Leakage 536
How to Examine Fuel System for Leakage 536
Handle Cylinder Cut-out Mode Operation 538
Handle No-Injection Cranking Operation 539
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 540
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 540
Examine Installed Condition of Cylinder Heads and Manifolds 541
How to Examine Installed Condition of Cylinder Heads and Manifolds 541
Examine Engine Piping for Damage and Looseness 542
How to Examine Engine Piping for Damage and Looseness 542
Examine Alternator Belt 543
How to Examine Alternator Belt 543
Examine Automatic Tensioner 545
How to Examine Automatic Tensioner 545
Write Correction for Ash in Soot Accumulation to Engine Controller 547
How to Write Correction for Ash in Soot Accumulation to Engine Controller 547
Examine SCR Related Function 548
Examine DEF Pump Raised Pressure 552
Examine Injection Volume from DEF Injector 555
Examine DEF Line Heater Relay 1 560
Examine DEF Line Heater Relay 2 564
Examine DEF Pump Heater Relay 568
Examine DEF Tank Heater Valve 572
Examine SCR Denitration Efficiency 576
Clean DEF Tank 579
How to Clean DEF Tank 579
Clean DEF Tank Mounting Part 584
How to Clean DEF Tank Mounting Part 584
Clean DEF Pump 586
How to Clean DEF Pump 586
Power Train 592
Examine and Adjust HST Oil Pressure 592
How to Examine HST Oil Pressure 592
How to Adjust HST Oil Pressure 596
Bleed Air from HST Pump 599
How to Bleed Air from HST Pump 599
How to Bleed Air from Servo Valve of HST Pump 600
Examine Outlet Pressure of Solenoid Valve 602
How to Examine Outlet Pressure of Solenoid Valve 602
Examine Travel Deviation 609
How to Examine Travel Deviation 609
Examine Brake Performance Simply 611
How to Examine Brake Performance Simply 611
Examine and Adjust Deceleration/ Brake Pedal 612
How to Examine Deceleration/ Brake Pedal 612
How to Adjust Deceleration/ Brake Pedal 614
Move Machine When It Cannot Travel 616
How to Move Machine with Hydraulic Type Parking Brake Release System 616
How to Move Machine After You Remove Final Drive Shaft 619
Undercarriage and Frame 620
Examine and Adjust Idler Clearance 620
How to Adjust Idler Clearance 620
Examine Sprocket Wear 621
How to Examine Sprocket Wear 621
Examine and Adjust Track Tension 622
How to Examine Track Tension 622
How to Adjust Track Tension 622
Hydraulic System 623
Release Remained Pressure in Hydraulic Circuit 623
How to Release Remained Pressure in Hydraulic System 623
Examine and Adjust Work Equipment Circuit Oil Pressure 624
How to Examine Work Equipment Circuit Oil Pressure 624
How to Adjust Work Equipment Circuit Oil Pressure 626
Examine and Adjust Oil Pressure in Control Circuit 627
How to Examine Oil Pressure in Control Circuit 627
How to Adjust Oil Pressure in Control Circuit 629
Examine Outlet Pressure of EPC Solenoid Valve 630
How to Examine Outlet Pressure of EPC Solenoid Valve 630
Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 633
How to Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 633
Examine Cooling Fan Speed 635
How to Examine Cooling Fan Speed 635
Examine Cooling Fan Circuit Oil Pressure 636
How to Examine Cooling Fan Circuit Oil Pressure 636
Bleed Air in Cooling Fan Pump 638
How to Bleed Air in Cooling Fan Pump 638
Examine Parts Which Cause Hydraulic Drift of Work Equipment 639
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 639
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 639
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 640
Examine Oil Leakage from Work Equipment Cylinder 641
How to Examine Internal Oil Leakage of Work Equipment Cylinder 641
Bleed Air from Work Equipment Cylinders 644
How to Bleed Air from Work Equipment Cylinder 644
Work Equipment 645
Shim Adjustment of Center Ball 645
How to Adjust Shim of Center Ball 645
Examine and Adjust Play of Blade Electric Lever 646
How to Examine Play of Blade Electric Lever 648
How to Adjust Play of Blade Electric Lever 648
How to Replace Universal Joint 649
CAB Related Parts 656
Examine and Adjust Operator Cab 656
How to Examine Operator Cab 656
How to Adjust Operator Cab 658
Electrical System 661
Set and Operate Machine Monitor 661
Operator Mode 665
Function to Show Technician Identification Status Screen 665
Function to Show Operator Identification Input Screen 665
Examine Function by LCD (Liquid Crystal Display) 666
Examine Function of Service Meter 666
How to Set Usage Limitation and Change Maintenance Password 666
Service Mode 669
How to Operate Service Mode 669
How to See Pre-defined Monitoring Information 670
How to Examine Monitoring Information 684
Abnormality Record Menu 705
How to See Maintenance Record 709
Maintenance Mode Setting 710
How to Set Phone Number Entry 714
Default Setting Menu 715
Testing Menu 724
Adjustment Menu 733
No-Injection Cranking Operation 796
KOMTRAX Settings Menu 798
How to Show Service Message 800
How to Start Up KOMTRAX System 802
Adjust After Replacement of HST Controller 809
How to Adjust After Replacement of HST Controller 809
Adjust After Replacement of Electric and Hydraulic Equipment 814
Adjust Rearview Camera Angle 816
How to Adjust Rearview Camera Angle 816
Set Region of Bluetooth(R) Compatible Radio 817
How to Set Region of Bluetooth(R) Compatible Radio 817
Handle Voltage Circuit of Engine Controller 819
Handle Battery Disconnect Switch 820
Examine Diodes 821
How to Examine Diodes by Digital Tester 821
How to Examine Diodes by Analog Tester 821
Pm Clinic 822
Pm Clinic Service 822
Pm Clinic Check Sheet: D71EX-24 824
Pm Clinic Check Sheet: D71EX-24E0 832
Pm Clinic Check Sheet: D71PX-24 840
Pm Clinic Check Sheet: D71PX-24E0 847
Pm Clinic Check Sheet for Undercarriage: D71EX-24 854
Pm Clinic Check Sheet for Undercarriage: D71EX-24E0 862
Pm Clinic Check Sheet for Undercarriage: D71PX-24 870
Pm Clinic Check Sheet for Undercarriage: D71PX-24E0 878
40 Troubleshooting 887
Table of Contents 888
Precautions Before Work 900
Related Information to Troubleshooting 901
General Troubleshooting Points 901
Troubleshooting Points for Urea SCR System 902
Sequence of Events in Troubleshooting 916
Checks Before Troubleshooting 918
Inspection Procedure Before Troubleshooting 920
Walk-Around Check 920
Test in Accordance with Testing Procedure 922
Examine Fuel Level and Type 922
Examine for Impure Ingredient in Fuel 922
Examine DEF Level and Type 923
Examine Fuel Prefilter 923
Examine Fuel Main Filter 925
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 926
Examine Coolant Level (Expansion Tank) 927
Examine Air Cleaner Clogging 928
Clean Outer Element 929
Replace Element 931
Examine Hydraulic Oil Level 932
Examine Hydraulic Oil Strainer 933
Examine Hydraulic Oil Filter 936
Examine Oil Level in Final Drive Case 938
Bleed Air from Fuel System 938
Bleed Air from Hydraulic System 938
How to Examine Electric Equipment 938
How to Connect Adapter for Troubleshooting Controller 945
How to Connect Adapter for Troubleshooting Machine Monitor 945
How to Connect Adapter for Troubleshooting HST Controller 945
How to Connect Adapter for Troubleshooting Work Equipment Controller 946
How to Connect Adapter for Troubleshooting Gateway Function Controller 946
How to Connect Adapter for Troubleshooting Engine Controller 947
How to Connect Connectors for Engine Related Parts 948
Procedure for Troubleshooting 952
Information Shown in Troubleshooting Table 954
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 956
Connectors List 959
Connector Layout 969
Connector Contact Connection Table 979
T-Branch Box and T-Branch Adapter Table 1026
Fuse Location Table 1032
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1036
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1040
Failure Code Table 1042
Troubleshooting by Failure Code (Display of Code) 1064
Failure Code [6091NX] 1064
Failure Code [989L00] 1066
Failure Code [989M00] 1067
Failure Code [989N00] 1068
Failure Code [A1U0N3] 1069
Failure Code [A1U0N4] 1071
Failure Code [A900FR] 1073
Failure Code [A900N6] 1074
Failure Code [A900NY] 1075
Failure Code [AA10NX] 1076
Failure Code [AB00KE] 1078
Failure Code [AQ10N3] 1080
Failure Code [AS00N3] 1082
Failure Code [AS00R2] 1084
Failure Code [AS00R3] 1085
Failure Code [AS00R4] 1086
Failure Code [AS00R5] 1087
Failure Code [AS00R6] 1088
Failure Code [AS00ZK] 1089
Failure Code [AS10KM] 1090
Failure Code [AS10NR] 1091
Failure Code [AS10NT] 1092
Failure Code [B@BAZG] 1093
Failure Code [B@BCNS] 1094
Failure Code [B@BCQA] 1095
Failure Code [B@BCZK] 1097
Failure Code [B@CRNS] 1099
Failure Code [B@CRZG] 1100
Failure Code [CA115] 1101
Failure Code [CA122] 1102
Failure Code [CA123] 1105
Failure Code [CA131] 1108
Failure Code [CA132] 1110
Failure Code [CA144] 1112
Failure Code [CA145] 1115
Failure Code [CA153] 1117
Failure Code [CA154] 1120
Failure Code [CA187] 1123
Failure Code [CA221] 1125
Failure Code [CA222] 1127
Failure Code [CA227] 1129
Failure Code [CA234] 1130
Failure Code [CA238] 1131
Failure Code [CA239] 1133
Failure Code [CA249] 1135
Failure Code [CA256] 1137
Failure Code [CA271] 1139
Failure Code [CA272] 1141
Failure Code [CA281] 1143
Failure Code [CA322] 1144
Failure Code [CA323] 1146
Failure Code [CA324] 1148
Failure Code [CA325] 1150
Failure Code [CA331] 1152
Failure Code [CA332] 1154
Failure Code [CA343] 1156
Failure Code [CA351] 1157
Failure Code [CA352] 1158
Failure Code [CA356] 1161
Failure Code [CA357] 1163
Failure Code [CA386] 1165
Failure Code [CA428] 1166
Failure Code [CA429] 1168
Failure Code [CA435] 1170
Failure Code [CA441] 1172
Failure Code [CA442] 1175
Failure Code [CA449] 1176
Failure Code [CA451] 1180
Failure Code [CA452] 1183
Failure Code [CA515] 1185
Failure Code [CA516] 1187
Failure Code [CA553] 1189
Failure Code [CA555] 1190
Failure Code [CA556] 1191
Failure Code [CA559] 1192
Failure Code [CA595] 1196
Failure Code [CA687] 1197
Failure Code [CA689] 1199
Failure Code [CA691] 1204
Failure Code [CA692] 1206
Failure Code [CA697] 1208
Failure Code [CA698] 1209
Failure Code [CA731] 1210
Failure Code [CA778] 1212
Failure Code [CA1117] 1217
Failure Code [CA1664] 1218
Failure Code [CA1669] 1221
Failure Code [CA1673] 1222
Failure Code [CA1677] 1223
Failure Code [CA1678] 1224
Failure Code [CA1682] 1225
Failure Code [CA1683] 1230
Failure Code [CA1684] 1232
Failure Code [CA1686] 1234
Failure Code [CA1691] 1235
Failure Code [CA1694] 1238
Failure Code [CA1695] 1241
Failure Code [CA1696] 1242
Failure Code [CA1712] 1244
Failure Code [CA1713] 1247
Failure Code [CA1714] 1249
Failure Code [CA1715] 1250
Failure Code [CA1776] 1251
Failure Code [CA1777] 1254
Failure Code [CA1843] 1257
Failure Code [CA1844] 1259
Failure Code [CA1879] 1262
Failure Code [CA1881] 1264
Failure Code [CA1883] 1266
Failure Code [CA1885] 1270
Failure Code [CA1887] 1272
Failure Code [CA1921] 1274
Failure Code [CA1922] 1277
Failure Code [CA1942] 1282
Failure Code [CA1993] 1283
Failure Code [CA2185] 1286
Failure Code [CA2186] 1287
Failure Code [CA2249] 1289
Failure Code [CA2265] 1290
Failure Code [CA2266] 1292
Failure Code [CA2271] 1294
Failure Code [CA2272] 1297
Failure Code [CA2311] 1300
Failure Code [CA2349] 1301
Failure Code [CA2353] 1304
Failure Code [CA2357] 1306
Failure Code [CA2381] 1307
Failure Code [CA2382] 1310
Failure Code [CA2383] 1313
Failure Code [CA2386] 1316
Failure Code [CA2387] 1318
Failure Code [CA2555] 1319
Failure Code [CA2556] 1322
Failure Code [CA2637] 1325
Failure Code [CA2639] 1327
Failure Code [CA2771] 1330
Failure Code [CA2777] 1336
Failure Code [CA2976] 1339
Failure Code [CA3133] 1341
Failure Code [CA3134] 1343
Failure Code [CA3135] 1345
Failure Code [CA3142] 1349
Failure Code [CA3143] 1350
Failure Code [CA3144] 1351
Failure Code [CA3146] 1353
Failure Code [CA3147] 1354
Failure Code [CA3148] 1355
Failure Code [CA3151] 1357
Failure Code [CA3165] 1363
Failure Code [CA3229] 1365
Failure Code [CA3231] 1367
Failure Code [CA3232] 1369
Failure Code [CA3235] 1373
Failure Code [CA3239] 1375
Failure Code [CA3241] 1378
Failure Code [CA3242] 1381
Failure Code [CA3251] 1384
Failure Code [CA3253] 1386
Failure Code [CA3254] 1389
Failure Code [CA3255] 1392
Failure Code [CA3256] 1394
Failure Code [CA3311] 1396
Failure Code [CA3312] 1398
Failure Code [CA3313] 1401
Failure Code [CA3314] 1402
Failure Code [CA3315] 1403
Failure Code [CA3316] 1405
Failure Code [CA3317] 1406
Failure Code [CA3318] 1407
Failure Code [CA3319] 1409
Failure Code [CA3321] 1410
Failure Code [CA3322] 1412
Failure Code [CA3419] 1414
Failure Code [CA3421] 1416
Failure Code [CA3497] 1418
Failure Code [CA3498] 1419
Failure Code [CA3543] 1420
Failure Code [CA3545] 1425
Failure Code [CA3547] 1427
Failure Code [CA3558] 1428
Failure Code [CA3559] 1430
Failure Code [CA3562] 1432
Failure Code [CA3563] 1434
Failure Code [CA3567] 1437
Failure Code [CA3568] 1440
Failure Code [CA3571] 1446
Failure Code [CA3572] 1448
Failure Code [CA3574] 1450
Failure Code [CA3575] 1453
Failure Code [CA3577] 1455
Failure Code [CA3578] 1457
Failure Code [CA3582] 1459
Failure Code [CA3583] 1466
Failure Code [CA3596] 1468
Failure Code [CA3649] 1471
Failure Code [CA3681] 1473
Failure Code [CA3682] 1476
Failure Code [CA3713] 1478
Failure Code [CA3717] 1481
Failure Code [CA3718] 1482
Failure Code [CA3725] 1483
Failure Code [CA3741] 1486
Failure Code [CA3748] 1487
Failure Code [CA3751] 1489
Failure Code [CA3755] 1491
Failure Code [CA3866] 1493
Failure Code [CA3867] 1497
Failure Code [CA3868] 1500
Failure Code [CA3899] 1504
Failure Code [CA3911] 1506
Failure Code [CA3912] 1510
Failure Code [CA3932] 1512
Failure Code [CA3933] 1514
Failure Code [CA3934] 1516
Failure Code [CA3935] 1519
Failure Code [CA3936] 1521
Failure Code [CA4151] 1523
Failure Code [CA4152] 1527
Failure Code [CA4155] 1531
Failure Code [CA4156] 1534
Failure Code [CA4157] 1537
Failure Code [CA4158] 1539
Failure Code [CA4159] 1540
Failure Code [CA4161] 1541
Failure Code [CA4162] 1544
Failure Code [CA4163] 1547
Failure Code [CA4164] 1549
Failure Code [CA4165] 1551
Failure Code [CA4166] 1553
Failure Code [CA4168] 1555
Failure Code [CA4169] 1558
Failure Code [CA4171] 1560
Failure Code [CA4249] 1563
Failure Code [CA4251] 1565
Failure Code [CA4259] 1567
Failure Code [CA4261] 1570
Failure Code [CA4277] 1573
Failure Code [CA4281] 1577
Failure Code [CA4459] 1580
Failure Code [CA4461] 1583
Failure Code [CA4658] 1586
Failure Code [CA4731] 1590
Failure Code [CA4732] 1591
Failure Code [CA4739] 1592
Failure Code [CA4768] 1593
Failure Code [CA4769] 1595
Failure Code [CA4842] 1598
Failure Code [CA4952] 1602
Failure Code [CA5115] 1604
Failure Code [CA5179] 1607
Failure Code [CA5181] 1609
Failure Code [CA5383] 1611
Failure Code [D130KA] 1613
Failure Code [D130KB] 1616
Failure Code [D130KY] 1618
Failure Code [D19JKZ] 1620
Failure Code [D19UKA] 1623
Failure Code [D19UKB] 1625
Failure Code [D19UMC] 1627
Failure Code [D811MC] 1629
Failure Code [D862KA] 1630
Failure Code [D8ALKA] 1632
Failure Code [D8ALKB] 1634
Failure Code [D8AQKR] 1636
Failure Code [D8ARKR] 1638
Failure Code [D8G1KT] 1640
Failure Code [D8G6KT] 1641
Failure Code [DAF0MB] 1642
Failure Code [DAF0MC] 1643
Failure Code [DAF8KB] 1644
Failure Code [DAF9KQ] 1645
Failure Code [DAFGMC] 1646
Failure Code [DAFLKA] 1647
Failure Code [DAFLKB] 1649
Failure Code [DAFQKR] 1652
Failure Code [DAJ000] 1653
Failure Code [DAJ0KQ] 1654
Failure Code [DAJ0KT] 1655
Failure Code [DAJ0MC] 1656
Failure Code [DAJ1KK] 1657
Failure Code [DAJ2KK] 1659
Failure Code [DAJ2KT] 1661
Failure Code [DAJ5KK] 1662
Failure Code [DAJ6KK] 1665
Failure Code [DAJLKA] 1667
Failure Code [DAJLKB] 1669
Failure Code [DAJPMA] 1671
Failure Code [DAJQKR] 1672
Failure Code [DAJRKR] 1673
Failure Code [DB2QKR] 1674
Failure Code [DB2RKR] 1680
Failure Code [DB90KT] 1686
Failure Code [DB90MC] 1687
Failure Code [DB91KK] 1688
Failure Code [DB92KK] 1690
Failure Code [DB92KT] 1692
Failure Code [DB95KK] 1693
Failure Code [DB97KK] 1695
Failure Code [DB99KQ] 1697
Failure Code [DB9LKA] 1698
Failure Code [DB9LKB] 1700
Failure Code [DB9QKR] 1702
Failure Code [DB9RKR] 1703
Failure Code [DD12KA] 1704
Failure Code [DD12KB] 1706
Failure Code [DD13KA] 1708
Failure Code [DD13KB] 1710
Failure Code [DD14KA] 1712
Failure Code [DD14KB] 1715
Failure Code [DDE9KA] 1718
Failure Code [DDE9KB] 1720
Failure Code [DDKAKA] 1722
Failure Code [DDKAKB] 1724
Failure Code [DDKFL4] 1726
Failure Code [DDKGL4] 1728
Failure Code [DDKHKA] 1730
Failure Code [DDKHKB] 1732
Failure Code [DDNLKA] 1734
Failure Code [DDNLKB] 1737
Failure Code [DDP6KA] 1740
Failure Code [DDP6KB] 1743
Failure Code [DDP6MA] 1745
Failure Code [DDU1FS] 1747
Failure Code [DDU1KA] 1749
Failure Code [DDU1KY] 1752
Failure Code [DFA4KX] 1754
Failure Code [DFA4KZ] 1755
Failure Code [DFA4L8] 1756
Failure Code [DFA5KA] 1757
Failure Code [DFA5KB] 1759
Failure Code [DFA6KA] 1761
Failure Code [DFA6KB] 1763
Failure Code [DFA7KX] 1765
Failure Code [DFA7KZ] 1766
Failure Code [DFA7L8] 1767
Failure Code [DFA8KA] 1768
Failure Code [DFA8KB] 1771
Failure Code [DFA9KA] 1773
Failure Code [DFA9KB] 1776
Failure Code [DFAAKX] 1778
Failure Code [DFAAKZ] 1779
Failure Code [DFAAL8] 1780
Failure Code [DFABKA] 1781
Failure Code [DFABKY] 1784
Failure Code [DFACKA] 1786
Failure Code [DFACKY] 1789
Failure Code [DGS1KA] 1791
Failure Code [DGS1KX] 1794
Failure Code [DH21KA] 1795
Failure Code [DH21KB] 1797
Failure Code [DHA4KA] 1799
Failure Code [DHAAMA] 1801
Failure Code [DHACMA] 1803
Failure Code [DHH7KA] 1805
Failure Code [DHH7KB] 1807
Failure Code [DHH8KA] 1809
Failure Code [DHH8KB] 1811
Failure Code [DHH9KA] 1813
Failure Code [DHH9KB] 1815
Failure Code [DHHAKA] 1817
Failure Code [DHHAKB] 1820
Failure Code [DHZ1KX] 1822
Failure Code [DK30KA] 1824
Failure Code [DK30KB] 1827
Failure Code [DK30KX] 1829
Failure Code [DK30KZ] 1830
Failure Code [DK30L8] 1831
Failure Code [DK31KA] 1832
Failure Code [DK31KB] 1835
Failure Code [DK40KA] 1837
Failure Code [DK40KB] 1840
Failure Code [DK55KX] 1842
Failure Code [DK55KZ] 1843
Failure Code [DK55L8] 1844
Failure Code [DK56KA] 1845
Failure Code [DK56KB] 1848
Failure Code [DK57KA] 1850
Failure Code [DK57KB] 1853
Failure Code [DK80KR] 1855
Failure Code [DK80KT] 1858
Failure Code [DLM0KX] 1860
Failure Code [DLM1KA] 1861
Failure Code [DLM1KB] 1863
Failure Code [DLM1MA] 1865
Failure Code [DLM2KA] 1866
Failure Code [DLM2KB] 1868
Failure Code [DLM2MA] 1870
Failure Code [DLM3KA] 1871
Failure Code [DLM3KB] 1873
Failure Code [DLM3MB] 1875
Failure Code [DN21FS] 1876
Failure Code [DN21KA] 1878
Failure Code [DN21KY] 1881
Failure Code [DR21KX] 1883
Failure Code [DR31KX] 1884
Failure Code [DV20KB] 1885
Failure Code [DW4BKA] 1887
Failure Code [DW4BKB] 1889
Failure Code [DW4BKY] 1891
Failure Code [DW7BKA] 1893
Failure Code [DW7BKB] 1895
Failure Code [DW7EKA] 1897
Failure Code [DW7EKB] 1900
Failure Code [DW7EKY] 1903
Failure Code [DWH1KA] 1905
Failure Code [DWH1KB] 1907
Failure Code [DWN5KA] 1909
Failure Code [DWN5KB] 1911
Failure Code [DWN5KY] 1913
Failure Code [DXA4KA] (Applicable Machine: 70002 to 72160) 1915
Failure Code [DXA4KA] (Applicable Machine: 72161 and Up) 1917
Failure Code [DXA4KB] (Applicable Machine: 70002 to 72160) 1919
Failure Code [DXA4KB] (Applicable Machine: 72161 and Up) 1921
Failure Code [DXA4KY] (Applicable Machine: 70002 to 72160) 1923
Failure Code [DXA4KY] (Applicable Machine: 72161 and Up) 1925
Failure Code [DXA5KA] (Applicable Machine: 70002 to 72160) 1927
Failure Code [DXA5KA] (Applicable Machine: 72161 and Up) 1929
Failure Code [DXA5KB] (Applicable Machine: 70002 to 72160) 1931
Failure Code [DXA5KB] (Applicable Machine: 72161 and Up) 1933
Failure Code [DXA5KY] (Applicable Machine: 70002 to 72160) 1935
Failure Code [DXA5KY] (Applicable Machine: 72161 and Up) 1937
Failure Code [DXA6KA] (Applicable Machine: 70002 to 72160) 1939
Failure Code [DXA6KA] (Applicable Machine: 72161 and Up) 1941
Failure Code [DXA6KB] (Applicable Machine: 70002 to 72160) 1943
Failure Code [DXA6KB] (Applicable Machine: 72161 and Up) 1945
Failure Code [DXA6KY] (Applicable Machine: 70002 to 72160) 1947
Failure Code [DXA6KY] (Applicable Machine: 72161 and Up) 1949
Failure Code [DXA7KA] (Applicable Machine: 70002 to 72160) 1951
Failure Code [DXA7KA] (Applicable Machine: 72161 and Up) 1953
Failure Code [DXA7KB] (Applicable Machine: 70002 to 72160) 1955
Failure Code [DXA7KB] (Applicable Machine: 72161 and Up) 1957
Failure Code [DXA7KY] (Applicable Machine: 70002 to 72160) 1959
Failure Code [DXA7KY] (Applicable Machine: 72161 and Up) 1961
Failure Code [DXE0KA] 1963
Failure Code [DXE0KB] 1965
Failure Code [DXE0KY] 1966
Failure Code [DXHRKA] 1968
Failure Code [DXHRKB] 1970
Failure Code [DXHRKY] 1972
Failure Code [DXHSKA] 1974
Failure Code [DXHSKB] 1976
Failure Code [DXHSKY] 1978
Failure Code [DXHTKA] 1980
Failure Code [DXHTKB] 1982
Failure Code [DXHTKY] 1984
Failure Code [DXHUKA] 1986
Failure Code [DXHUKB] 1988
Failure Code [DXHUKY] 1990
Failure Code [DXHWKA] 1992
Failure Code [DXHWKB] 1994
Failure Code [DXHWKY] 1995
Failure Code [DXHXKA] 1997
Failure Code [DXHXKB] 1999
Failure Code [DXHXKY] 2000
Failure Code [DXJ4KA] 2002
Failure Code [DXJ4KB] 2004
Failure Code [DXJAKA] 2006
Failure Code [DXJAKB] 2008
Failure Code [DXJAKY] 2010
Failure Code [DXJCKA] 2012
Failure Code [DXJCKB] 2014
Failure Code [DXJCKY] 2016
Failure Code [DXJDKA] 2018
Failure Code [DXJDKB] 2020
Failure Code [DXJDKY] 2022
Failure Code [DXK1KA] 2024
Failure Code [DXK1KB] 2026
Failure Code [DXK1KY] 2028
Failure Code [DXK2KA] 2030
Failure Code [DXK2KB] 2032
Failure Code [DXK2KY] 2034
Failure Code [F311KA] 2036
Failure Code [F311KB] 2038
Failure Code [F312KA] 2040
Failure Code [F312KB] 2042
Failure Code [F313KA] 2044
Failure Code [F313KB] 2046
Failure Code [F314KA] 2049
Failure Code [F314KB] 2051
Failure Code [F315KB] 2053
Failure Code [F315KY] 2055
Failure Code [F316KB] 2057
Failure Code [F316KY] 2059
Failure Code [F318KB] 2061
Failure Code [F318KY] 2064
Failure Code [F31AKB] 2066
Failure Code [F31AKY] 2068
Failure Code [F31BKB] 2070
Failure Code [F31BKY] 2072
Failure Code [F31CKB] 2074
Failure Code [F31CKY] 2076
Failure Code [F31DKB] 2078
Failure Code [F31DKY] 2080
Failure Code [F31EKB] 2082
Failure Code [F31EKY] 2084
Failure Code [FS10ZE] 2086
Failure Code [M620KA] 2087
Failure Code [M620KB] 2089
Failure Code [M620KY] 2090
Troubleshooting of Electrical System (E-Mode) 2092
Engine Does Not Start (Engine Does Not Crank) 2092
Manual Preheating System Does Not Operate 2098
Automatic Preheating System Does Not Operate 2101
While Preheating is in Operation, Preheating Monitor Does Not Come On 2103
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2105
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 2108
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2109
Charge Level Monitor Comes On in Red While Engine is in Operation 2110
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 2111
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 2112
HST Charge Pressure Monitor Comes On in Red While Engine Runs 2113
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2114
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs 2115
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2116
DEF Level is Not Shown Correctly 2117
Fuel Gauge Does Not Show Normally 2120
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2123
Operation Mode Does Not Change 2124
When You Operate Customize Switch Does Not Show Customize Screen 2125
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 2126
Service Meter is Not Shown While Starting Switch is in OFF Position 2127
Service Mode Cannot be Selected 2128
Work Equipment Does Not Operate 2129
Foot Heater Does Not Operate 2131
Horn Does Not Sound 2137
Horn Does Not Stop 2139
Backup Alarm Does Not Sound 2140
Backup Alarm Does Not Stop Operation 2141
Headlamp Does Not Come On 2142
Rear Lamp Does Not Come On 2146
No Wiper Operates 2149
Front Wiper Does Not Operate 2151
Rear Wiper Does Not Operate 2155
Left Door Wiper Does Not Operate 2159
Right Door Wiper Does Not Operate 2163
Front Washer Does Not Operate 2167
Rear Washer Does Not Operate 2169
Left Door Washer Does Not Operate 2171
Right Door Washer Does Not Operate 2173
KOMTRAX System Does Not Operate Correctly 2175
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2176
Information Shown in Troubleshooting Table (H-Mode) 2176
Failure Mode and Cause Table 2177
R H and L H Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) 2183
R H or L H Track Cannot Travel FORWARD and REVERSE (One of R H or L H Travel Systems Cannot Operate) 2185
R H or L H Track Cannot Travel FORWARD or REVERSE (Only One of the Travel Systems Cannot Operate in One Direction) 2187
Travel Speed or Power is Low 2189
Speed Range Does Not Change 2191
Shock is Large When Machine Moves Off or Stops 2192
Travel Deviation is Large 2193
Machine Drift on a Slope is Large 2196
Engine Speed Drops Largely or Engine Stops 2198
Unusual Noise is Heard from Around HST Pump or Motor 2200
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 2202
All Work Equipment Speed or Power is Low 2204
Blade Lift Speed or Power is Low 2205
Blade Tilt Speed or Power is Low 2207
Blade Angle Speed or Power is Low 2208
Hydraulic Drift of Lifted Ripper is Large 2210
Time Lag of Blade Lift is Large 2211
Hydraulic Drift of Blade Lift is Large 2212
Hydraulic Drift of Tilted Blade is Large 2213
Hydraulic Drift of Lifted Ripper is Large 2214
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 2215
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2216
Unusual Noise is Heard from Around Fan 2218
Troubleshooting of Engine (S-Mode) 2219
Information Shown in Troubleshooting Table (S-Mode) 2219
Engine Does Not Crank When Starting Switch is Turned to Start Position 2220
Engine Cranks but No Exhaust Smoke Comes Out 2221
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2222
Engine Startability is Unsatisfactory 2224
Engine Does Not Pick Up Smoothly 2226
Engine Stops During Operation 2228
Engine Does Not Rotate Smoothly 2230
Engine Lacks Output (or Lacks Power) 2231
KDPF Becomes Clogged in a Short Time 2233
Engine Oil Consumption is Excessive 2235
Engine Oil Becomes Dirty Quickly 2236
Fuel Consumption is Excessive 2237
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2238
Engine Oil Pressure Drops 2239
Fuel Mixes Into Engine Oil 2241
Water Mixes Into Engine Oil (Milky) 2242
Coolant Temperature Increases Too High (Overheat) 2243
Unusual Noise is Heard 2244
Vibration is Excessive 2245
Air Cannot be Bled from Fuel Circuit 2246
Active Regeneration is Done Frequently 2247
Active Regeneration Continues Long 2249
White Smoke is Exhausted During Active Regeneration 2250
DEF Consumption is Excessive 2251
There is an Unusual Smell (Irritating Odor) 2253
Foreign Materials Enter DEF (DEF Increases) 2254
50 Disassembly and Assembly 2255
Table of Contents 2256
Precautions Before Work 2262
Related Information on Disassembly and Assembly 2263
How to Read This Manual 2263
Coating Materials List 2264
Special Tool List 2269
Sketches of Special Tools 2289
Prepare 2301
Drain and Add Coolant 2301
How to Drain Coolant 2302
How to Add Coolant 2303
Drain and Add Hydraulic Oil 2306
How to Drain Hydraulic Oil 2307
How to Add Hydraulic Oil 2307
Drain and Add Fuel 2309
How to Drain Fuel 2309
How to Add Fuel 2310
Collect and Refill Refrigerant 2311
How to Collect Refrigerant 2312
How to Refill Refrigerant 2312
Engine and Cooling System 2313
Remove and Install Supply Pump Assembly 2313
How to Remove Supply Pump Assembly 2314
How to Install Supply Pump Assembly 2317
Remove and Install Injector Assembly 2322
How to Remove Injector Assembly 2323
How to Install Injector Assembly 2333
Remove and Install Cylinder Head Assembly 2348
How to Remove Cylinder Head Assembly 2350
How to Install Cylinder Head Assembly 2364
Remove and Install EGR Valve Assembly 2385
How to Remove EGR Valve Assembly 2386
How to Install EGR Valve Assembly 2387
Remove and Install EGR Cooler Assembly 2388
How to Remove EGR Cooler Assembly 2389
How to Install EGR Cooler Assembly 2390
Remove and Install Starter Assembly 2393
How to Remove Starting Motor Assembly 2394
How to Install Starting Motor Assembly 2396
Remove and Install Alternator Belt 2399
How to Remove Alternator Belt 2400
How to Install Alternator Belt 2401
Remove and Install Automatic Tensioner 2403
How to Remove Auto-Tensioner 2403
How to Install Auto-Tensioner 2404
Remove and Install Radiator Assembly 2405
How to Remove Radiator Assembly 2406
How to Install Radiator Assembly 2411
Remove and Install Hydraulic Oil Cooler Assembly 2416
How to Remove Hydraulic Oil Cooler Assembly 2417
How to Install Hydraulic Oil Cooler Assembly 2421
Remove and Install Aftercooler Assembly 2425
How to Remove Aftercooler Assembly 2426
How to Install Aftercooler Assembly 2429
Remove and Install Cooling Fan Drive Assembly 2433
How to Remove Cooling Fan Drive Assembly 2434
How to Install Cooling Fan Drive Assembly 2438
Remove and Install Cooling Fan Motor Assembly 2443
How to Remove Cooling Fan Motor Assembly 2444
How to Install Cooling Fan Motor Assembly 2447
Remove and Install Engine and HST Pump Assembly 2450
How to Remove Engine and HST Pump Assembly 2452
How to Install Engine and HST Pump Assembly 2466
Remove and Install Engine Front Oil Seal 2482
How to Remove Engine Front Oil Seal 2483
How to Install Engine Front Oil Seal 2488
Remove and Install Engine Rear Oil Seal 2493
How to Remove Engine Rear Oil Seal 2494
How to Install Engine Rear Oil Seal 2496
Remove and Install Engine Hood Assembly 2503
How to Remove Engine Hood Assembly 2504
How to Install Engine Hood Assembly 2511
Remove and Install Fuel Tank Assembly 2518
How to Remove Fuel Tank Assembly 2520
How to Install Fuel Tank Assembly 2528
Remove and Install DEF Tank Assembly 2535
How to Remove DEF Tank Assembly 2536
How to Install DEF Tank Assembly 2541
Remove and Install DEF Tank Sensor Flange Assembly 2546
How to Remove DEF Tank Sensor Flange Assembly 2547
How to Install DEF Tank Sensor Flange Assembly 2548
Remove and Install DEF Tank Sensor 2551
How to Remove DEF Tank Sensor 2552
How to Install DEF Tank Sensor 2553
Remove and Install DEF Tank Strainer 2560
How to Remove DEF Tank Strainer 2560
How to Install DEF Tank Strainer 2561
Remove and Install KDPF Assembly 2562
How to Remove KDPF Assembly 2563
How to Install KDPF Assembly 2567
Disassemble and Assemble KDPF Assembly 2573
How to Disassemble KDPF Assembly 2574
How to Assemble KDPF Assembly 2579
Remove and Install SCR Assembly 2586
How to Remove SCR Assembly 2587
How to Install SCR Assembly 2589
Remove and Install KDPF and SCR Assembly 2591
How to Remove KDPF and SCR Assembly 2592
How to Install KDPF and SCR Assembly 2603
Remove and Install KCCV Assembly 2615
How to Remove KCCV Assembly 2616
How to Install KCCV Assembly 2618
Remove and Install VGT Assembly 2620
How to Remove VGT Assembly 2621
How to Install VGT Assembly 2623
Remove and Install DEF Mixing Tube 2627
How to Remove DEF Mixing Tube 2628
How to Install DEF Mixing Tube 2632
Remove and Install DEF Injector 2638
How to Remove DEF Injector 2639
How to Install DEF Injector 2642
Remove and Install DEF Pump 2645
How to Remove DEF Pump 2646
How to Install DEF Pump 2650
Remove and Install DEF Hose 2653
How to Remove DEF Hose 2654
How to Install DEF Hose 2664
Remove and Install Air Cleaner Assembly 2673
How to Remove Air Cleaner Assembly 2674
How to Install Air Cleaner Assembly 2676
Remove and Install Air Conditioner Compressor Assembly 2678
How to Remove Air Conditioner Compressor Assembly 2679
How to Install Air Conditioner Compressor Assembly 2681
Remove and Install Air Conditioner Condenser Assembly 2683
How to Remove Air Conditioner Condenser Assembly 2684
How to Install Air Conditioner Condenser Assembly 2688
Power Train 2692
Remove and Install Damper Assembly 2692
How to Remove Damper Assembly 2692
How to Install Damper Assembly 2693
Remove and Install HST Pump Assembly 2694
How to Remove HST Pump Assembly 2695
How to Install HST Pump Assembly 2701
Remove and Install HST Motor and Final Drive Assembly 2708
How to Remove HST Motor and Final Drive Assembly 2709
How to Install HST Motor and Final Drive Assembly 2716
Disassemble and Assemble Final Drive Assembly 2723
How to Disassemble Final Drive Assembly 2724
How to Assemble Final Drive Assembly 2730
Undercarriage and Frame 2739
Remove and Install Track Frame Assembly 2739
How to Remove Track Frame Assembly 2740
How to Install Track Frame Assembly 2755
Remove and Install Idler Assembly 2768
How to Remove Idler Assembly 2769
How to Install Idler Assembly 2772
Disassemble and Assemble Idler Assembly 2775
How to Disassemble Idler Assembly 2775
How to Assemble Idler Assembly 2777
Remove and Install Recoil Spring Assembly 2782
How to Remove Recoil Spring Assembly 2782
How to Install Recoil Spring Assembly 2783
Disassemble and Assemble Recoil Spring Assembly 2784
How to Disassemble Recoil Spring Assembly 2784
How to Assemble Recoil Spring Assembly 2787
Remove and Install Track Roller Assembly 2790
How to Remove Track Roller Assembly 2791
How to Install Track Roller Assembly 2793
Disassemble and Assemble Track Roller Assembly 2796
How to Disassemble Track Roller Assembly 2796
How to Assemble Track Roller Assembly 2798
Remove and Install Carrier Roller Assembly 2802
How to Remove Carrier Roller Assembly 2803
How to Install Carrier Roller Assembly 2804
Disassemble and Assemble Carrier Roller Assembly 2806
How to Disassemble Carrier Roller Assembly 2806
How to Assemble Carrier Roller Assembly 2807
Remove and Install Pivot Shaft Assembly 2810
How to Remove Pivot Shaft Assembly 2811
How to Install Pivot Shaft Assembly 2812
Separate and Connect Track Assembly 2815
How to Examine Before Separation of Track Assembly 2816
How to Separate Track Assembly (Standard) 2816
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2817
How to Install Track Assembly 2818
Disassemble and Assemble Track Assembly Generally 2821
How to Disassemble Full Track Shoe Assembly 2821
How to Assemble Full Track Shoe Assembly 2826
Disassemble and Assemble PLUS Type Track Assembly Generally 2840
Disassemble PLUS Type Track Assembly Generally 2841
How to Assemble PLUS Type Track Shoe Assembly Generally 2842
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2857
How to Disassemble One Track Link Assembly in Field (Track Assembly) 2858
How to Assemble One Track Link Assembly in Field (Track Assembly) 2859
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2866
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2867
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2869
Remove and Install Equalizer Bar Assembly 2873
How to Remove Equalizer Bar Assembly 2874
How to Install Equalizer Bar Assembly 2876
Disassemble and Assemble Equalizer Bar Bushing 2879
How to Disassemble Equalizer Bar Bushing 2880
How to Assemble Equalizer Bar Bushing 2881
Remove and Install Segment Teeth 2882
How to Remove Segment Teeth 2883
How to Install Segment Teeth 2884
Hydraulic System 2886
Remove and Install Hydraulic Tank Assembly 2886
How to Remove Hydraulic Tank Assembly 2887
How to Install Hydraulic Tank Assembly 2893
Remove and Install Control Valve Assembly 2900
How to Remove Control Valve Assembly 2902
How to Install Control Valve Assembly 2908
Work Equipment 2915
Remove and Install Ripper Assembly 2915
How to Remove Ripper Assembly 2917
How to Install Ripper Assembly 2929
Remove and Install Blade Assembly 2941
How to Remove Blade Assembly 2942
How to Install Blade Assembly 2946
Remove and Install Work Equipment Assembly 2950
How to Remove Work Equipment Assembly 2951
How to Install Work Equipment Assembly 2955
Disassemble and Assemble Blade Lift Cylinder Assembly 2959
How to Disassemble Blade Lift Cylinder Assembly 2959
How to Assemble Blade Lift Cylinder Assembly 2961
Disassemble and Assemble Blade Angle Cylinder Assembly 2964
How to Disassemble Blade Angle Cylinder Assembly 2964
How to Assemble Blade Angle Cylinder Assembly 2966
Disassemble and Assemble Blade Tilt Cylinder Assembly 2970
How to Disassemble Blade Tilt Cylinder Assembly 2970
How to Assemble Blade Tilt Cylinder Assembly 2972
Disassemble and Assemble Ripper Lift Cylinder Assembly 2975
How to Disassemble Ripper Lift Cylinder Assembly 2975
How to Assemble Ripper Lift Cylinder Assembly 2977
CAB Related Parts 2980
Remove and Install Operator Cab Assembly 2980
How to Remove Operator Cab Assembly 2981
How to Install Operator Cab Assembly 2991
Remove and Install Operator Cab Glass (Adhered Glass) 3001
How to Remove Operator Cab Glass (Adhered Glass) 3003
How to Install Operator Cab Glass (Adhered Glass) 3003
Remove and Install Air Conditioner Unit Assembly 3009
How to Remove Air Conditioner Unit Assembly 3010
How to Install Air Conditioner Unit Assembly 3015
Remove and Install Receiver Drier 3021
How to Remove Receiver Drier 3022
How to Install Receiver Drier 3023
Remove and Install Operator Seat 3025
How to Remove Operator Seat 3026
How to Install Operator Seat 3028
How to Remove and Install Seat Belt 3030
How to Remove Seat Belt 3031
How to Install Seatbelt 3032
Remove and Install Foot Heater Assembly 3033
How to Remove Foot Heater Assembly 3034
How to Install Foot Heater Assembly 3037
Disassemble and Assemble Foot Heater Assembly 3041
How to Disassemble Foot Heater Assembly 3042
How to Assemble Foot Heater Assembly 3043
Electrical System 3046
Remove and Install Engine Controller Assembly 3046
How to Remove Engine Controller Assembly 3047
How to Install Engine Controller Assembly 3049
Remove and Install HST Controller Assembly 3052
How to Remove HST Controller Assembly 3053
How to Install HST Controller Assembly 3053
Remove and Install Work Equipment Controller Assembly 3055
How to Remove Work Equipment Controller Assembly 3056
How to Install Work Equipment Controller Assembly 3056
Remove and Install Machine Monitor Assembly 3058
How to Remove Machine Monitor Assembly 3059
How to Install Machine Monitor Assembly 3060
Remove and Install Mass Air Flow and Temperature Sensor 3062
How to Remove Mass Air Flow and Temperature Sensor 3063
How to Install Mass Air Flow and Temperature Sensor 3064
Remove and Install KCCV Crankcase Pressure Sensor 3065
How to Remove KCCV Crankcase Pressure Sensor 3066
How to Install KCCV Crankcase Pressure Sensor 3066
Remove and Install KDPF Temperature Sensor 3068
How to Remove KDPF Temperature Sensor 3069
How to Install KDPF Temperature Sensor 3071
Remove and Install KDPF Differential Pressure Sensor 3075
How to Remove KDPF Differential Pressure Sensor 3076
How to Install KDPF Differential Pressure Sensor 3077
Remove and Install SCR Temperature Sensor 3080
How to Remove SCR Temperature Sensor 3081
How to Install SCR Temperature Sensor 3083
Remove and Install Ammonia Sensor 3085
How to Remove Ammonia Sensor 3086
How to Install Ammonia Sensor 3087
Remove and Install SCR Outlet NOx Sensor 3089
How to Remove SCR Outlet NOx Sensor 3090
How to Install SCR Outlet NOx Sensor 3092
Remove and Install Rearview Camera 3095
How to Remove Rearview Camera 3096
How to Install Rearview Camera 3097
Remove and Install Gateway Function Controller 3098
How to Remove Gateway Function Controller 3099
How to Install Gateway Function Controller 3100
Remove and Install IMU Sensor 3102
How to Remove IMU Sensor 3103
How to Install IMU Sensor 3104
60 Maintenance Standard 3105
Table of Contents 3106
Explanation of Terms for Maintenance Standard 3107
Engine and Cooling System 3109
Maintenance Standard for Engine Mount 3109
Maintenance Standard for Damper 3110
Maintenance Standard for Cooling System 3111
Maintenance Standard for Cooling Fan Motor 3112
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 3114
Power Train 3115
Maintenance Standard for HST Pump 3115
Maintenance Standard for EPC Valve of HST Pump 3116
Maintenance Standard for Tow Receiving Valve of HST Pump 3117
Maintenance Standard for HST Charge Pump 3118
Maintenance Standard for Servo Valve 3120
Maintenance Standard for HST Motor 3122
Maintenance Standard for Final Drive 3123
Maintenance Standard for Sprocket for Conventional Type Track Shoes 3125
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 3126
Maintenance Standard for Sprocket for PLUS Type Track Shoes 3128
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3129
Undercarriage and Frame 3131
Maintenance Standard for Suspension 3131
Maintenance Standard for Track Frame and Idler Cushion 3134
Maintenance Standard for Idler 3136
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 3138
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 3139
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 3140
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 3141
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 3142
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 3143
Maintenance Standard for Conventional Type Track Shoes 3144
Maintenance Standard for PLUS Type Track Shoes 3146
Maintenance Standard for Single Shoes 3148
Maintenance Standard for Swamp Shoes 3149
Hydraulic System 3150
Maintenance Standard for Hydraulic Tank 3150
Maintenance Standard for Work Equipment and Cooling Fan Pump 3151
Maintenance Standard for LS-EPC Valve 3152
Maintenance Standard for Control Valve 3153
Maintenance Standard for 5-Spool EPC and Solenoid Valve 3161
Maintenance Standard for EPC Valve 3162
Maintenance Standard for Angle Control EPC Valve 3163
Maintenance Standard for Quick Drop Valve 3164
Work Equipment 3166
Maintenance Standard for Front Work Equipment 3166
Maintenance Standard for Cutting Edge and End Bit 3169
Maintenance Standard for Blade Lift Cylinder 3170
Maintenance Standard for Blade Tilt Cylinder 3171
Maintenance Standard for Blade Angle Cylinder 3172
Maintenance Standard for Fixed Multi-Shank Ripper 3173
Maintenance Standard for Ripper Lift Cylinder 3175
CAB Related Parts 3176
Maintenance Standard for CAB Mount 3176
Electrical System 3177
Maintenance Standard for Steering Electric Lever 3177
80 Appendix 3179
Table of Contents 3180
Precautions Before Work 3181
Air Conditioner System 3182
Precautions for Refrigerant 3182
Air Conditioner Component 3183
Specifications of Air Conditioner 3186
Structure and Function of Refrigeration Cycle 3187
Outline of Refrigeration Cycle 3188
Component Parts of Air Conditioner System 3190
Air Conditioner Unit 3190
Configuration Diagram of Air Conditioner Unit 3190
Function of Air Conditioner Unit 3191
Component Parts of Air Conditioner Unit 3192
Function of Evaporator as Air Conditioner Unit Component 3192
Function of Heater Core as Air Conditioner Unit Component 3192
Function of Thermostat as Air Conditioner Unit Component 3192
Structure of Expansion Valve as Air Conditioner Unit Component 3193
Function of Expansion Valve as Air Conditioner Unit Component 3193
Operate Expansion Valve as Air Conditioner Unit Component 3193
Function of Dual Pressure Switch 3194
Function of Pressure Switch 3194
Compressor 3195
Structure of Compressor 3195
Specifications of Compressor 3195
Function of Compressor 3195
Condenser 3196
Structure of Condenser 3196
Specifications of Condenser 3196
Function of Condenser 3197
Receiver Drier 3198
Structure of Receiver Dryer 3198
Specifications of Receiver Dryer 3198
Function of Receiver Dryer 3198
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3200
Circuit Diagram of Air Conditioner 3203
System Diagram of Air Conditioner 3204
Control Function of Air Conditioner 3205
Locations of Air Conditioner Parts and Layout of Connectors 3206
Examine Relay 3210
How to Examine Relay 3210
Air Conditioner Troubleshooting Chart 1 3212
Air Conditioner Troubleshooting Chart 2 3213
Information Shown in Troubleshooting Table 3216
Troubleshooting for Condenser Fan 3217
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3220
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3224
Troubleshooting for Temperature Control Function 3227
Troubleshooting by Gauge Pressure 3231
Connect Service Tool 3233
How to Connect Service Tool 3233
Precautions for Disconnection and Connection of Air Conditioner Piping 3234
Handle Compressor Oil 3236
90 Circuit Diagrams 3239
Table of Contents 3240
How to Read the Codes for Electric Cable 3242
Hydraulic Circuit Diagram 3246
Symbols Used in Hydraulic Circuit Diagram 3246
Hydraulic Circuit Diagram 3251
Hydraulic Circuit Diagram (Combination of Forward, Blade LOWER, and Cooling Fan Turns Normally) 3253
Hydraulic Circuit Diagram (Combination of Blade RAISE, Reverse, and Cooling Fan Turns Normally) 3255
Electrical Circuit Diagram 3257
Symbols Used in Electric Circuit Diagram 3257
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (1/16) 3261
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (2/16) 3263
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (3/16) 3265
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (4/16) 3267
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (5/16) 3269
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (6/16) 3271
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (7/16) 3273
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (8/16) 3275
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (9/16) 3277
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (10/16) 3279
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (11/16) 3281
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (12/16) 3283
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (13/16) 3285
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (14/16) 3287
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (15/16) 3289
Electrical Circuit Diagram (Applicable Machine: 70002 to 70281) (16/16) 3291
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (1/17) 3293
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (2/17) 3295
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (3/17) 3297
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (4/17) 3299
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (5/17) 3301
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (6/17) 3303
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (7/17) 3305
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (8/17) 3307
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (9/17) 3309
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (10/17) 3311
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (11/17) 3313
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (12/17) 3315
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (13/17) 3317
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (14/17) 3319
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (15/17) 3321
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (16/17) 3323
Electrical Circuit Diagram (Applicable Machine: 70282 to 72160) (17/17) 3325
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (1/18) 3327
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (2/18) 3329
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (3/18) 3331
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (4/18) 3333
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (5/18) 3335
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (6/18) 3337
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (7/18) 3339
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (8/18) 3341
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (9/18) 3343
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (10/18) 3345
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (11/18) 3347
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (12/18) 3349
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (13/18) 3351
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (14/18) 3353
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (15/18) 3355
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (16/18) 3357
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (17/18) 3359
Electrical Circuit Diagram (Applicable Machine: 72161 and Up) (18/18) 3361
Index 3363

IMAGES PREVIEW OF THE MANUAL:

S.V 28/12/24