Complete service repair manual for Komatsu Bulldozers D37EXi, D37PXi, D39EXi, D39PXi, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Komatsu Bulldozer D37EXi, D37PXi, D39EXi, D39PXi workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN06593-06 – Bulldozer D37EXi-24, D37PXi-24, D39EXi-24, D39PXi-24 Shop Manual (SN80001&up).pdf
PRODUCT DETAILS:
Total Pages: 2,910 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
00 INDEX AND FOREWORD
01 SPECIFICATIONS
10 STRUCTURE AND FUNCTION
20 STANDARD VALUE TABLE
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
60 MAINTENANCE STANDARD.
80 APPENDIX
90 CIRCUIT DIAGRAMS
COVER…..1
00 INDEX AND FOREWORD…..3
INDEX…..4
ABBREVIATION LIST…..22
FOREWORD, SAFETY, BASIC INFORMATION…..28
HOW TO READ THE SHOP MANUAL…..28
SAFETY NOTICE FOR OPERATION…..30
PRECAUTIONS TO PREVENT FIRE…..38
ACTIONS IF FIRE OCCURS…..40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…..41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…..42
PRECAUTIONS FOR DEF…..43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…..43
PRECAUTIONS FOR ADDING…..43
PRECAUTIONS FOR STORING…..43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE…..43
THE OTHER PRECAUTIONS…..43
STORE AdBlue/DEF…..44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…..45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…..48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…..55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…..57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…..58
PRACTICAL USE OF KOMTRAX…..59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER…..60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…..60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…..61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…..62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…..64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…..68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…..69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…..71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…..72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…..74
HOW TO READ ELECTRICAL WIRE CODE…..75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…..79
STANDARD TIGHTENING TORQUE TABLE…..82
CONVERSION TABLE…..89
01 SPECIFICATIONS…..95
CONTENTS…..96
ABBREVIATION LIST…..97
SPECIFICATIONS…..103
SPECIFICATION DRAWING…..103
SPECIFICATION DRAWING: D37EXI-24…..104
SPECIFICATION DRAWING: D37PXI-24…..105
SPECIFICATION DRAWING: D39EXI-24…..106
SPECIFICATION DRAWING: D39PXI-24…..107
SPECIFICATIONS…..109
SPECIFICATIONS: D37EXI-24…..109
SPECIFICATIONS: D37PXI-24…..114
SPECIFICATIONS: D39EXI-24…..118
SPECIFICATIONS: D39PXI-24…..123
WEIGHT TABLE…..131
WEIGHT TABLE: D37EXI-24…..132
WEIGHT TABLE: D37PXI-24…..134
WEIGHT TABLE: D39EXI-24…..136
WEIGHT TABLE: D39PXI-24…..138
TABLE OF FUEL, COOLANT, AND LUBRICANTS…..142
10 STRUCTURE AND FUNCTION…..143
CONTENTS…..144
ABBREVIATION LIST…..147
UREA SCR SYSTEM…..153
LAYOUT DRAWING OF UREA SCR SYSTEM…..153
UREA SCR SYSTEM DIAGRAM…..155
FUNCTION OF UREA SCR SYSTEM…..156
FUNCTION OF AdBlue/DEF SYSTEM…..156
INDUCEMENT STRATEGY…..158
COMPONENT PARTS OF UREA SCR SYSTEM…..172
AdBlue/DEF MIXING TUBE…..172
SCR ASSEMBLY…..173
AdBlue/DEF TANK…..175
AdBlue/DEF PUMP…..177
AdBlue/DEF INJECTOR…..178
AdBlue/DEF HOSE…..179
AdBlue/DEF TANK HEATING VALVE…..180
BOOT-UP SYSTEM…..181
LAYOUT DRAWING OF BOOT-UP SYSTEM…..181
SYSTEM OPERATING LAMP SYSTEM…..182
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…..182
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM…..183
BATTERY DISCONNECT SWITCH…..184
FUNCTION OF BATTERY DISCONNECT SWITCH…..184
ENGINE SYSTEM…..185
LAYOUT DRAWING OF ENGINE SYSTEM…..185
ENGINE CONTROL SYSTEM…..187
LAYOUT OF ENGINE CONTROL SYSTEM…..187
ENGINE CONTROL SYSTEM DIAGRAM…..189
FUNCTION OF ENGINE CONTROL SYSTEM…..191
AUTOMATIC IDLE STOP SYSTEM…..193
AUTOMATIC IDLE STOP SYSTEM DIAGRAM…..193
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…..194
COMPONENT PARTS OF ENGINE SYSTEM…..196
DAMPER…..196
VARIABLE FLOW TURBOCHARGER…..197
EGR SYSTEM…..200
EGR VALVE…..203
EGR COOLER…..205
KCCV SYSTEM…..207
KCCV VENTILATOR…..210
EXHAUST THROTTLE VALVE…..212
KDOC…..213
COOLING SYSTEM…..216
LAYOUT DRAWING OF COOLING SYSTEM…..216
SPECIFICATIONS OF COOLING SYSTEM…..217
COOLING FAN CONTROL SYSTEM…..218
COOLING FAN CONTROL SYSTEM DIAGRAM…..218
FUNCTION OF COOLING FAN CONTROL SYSTEM…..219
COMPONENT PARTS OF COOLING SYSTEM…..221
COOLING FAN MOTOR…..221
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE…..226
HYDRAULIC OIL COOLER BYPASS VALVE…..228
HST CHARGE SAFETY VALVE…..229
CONTROL SYSTEM…..231
LAYOUT DRAWING OF CONTROL SYSTEM…..231
MACHINE MONITOR SYSTEM…..232
MACHINE MONITOR SYSTEM DIAGRAM…..232
FUNCTION OF MACHINE MONITOR SYSTEM…..233
KOMTRAX SYSTEM…..234
KOMTRAX SYSTEM DIAGRAM…..234
FUNCTION OF KOMTRAX SYSTEM…..235
COMPONENT PARTS OF CONTROL SYSTEM…..236
MACHINE MONITOR…..236
KOMTRAX TERMINAL…..251
HST CONTROLLER…..253
ENGINE CONTROLLER…..257
FUEL CONTROL DIAL…..264
DECELERATOR AND BRAKE POTENTIOMETER…..266
HYDRAULIC SYSTEM…..268
LAYOUT DRAWING OF HYDRAULIC SYSTEM…..268
CLSS…..269
STRUCTURE OF CLSS…..269
FUNCTION OF CLSS…..270
COMPONENT PARTS OF HYDRAULIC SYSTEM…..272
HYDRAULIC TANK…..272
WORK EQUIPMENT AND COOLING FAN PUMP…..274
LS VALVE…..281
PC VALVE…..282
CONTROL VALVE…..285
POWER TRAIN SYSTEM…..306
LAYOUT DRAWING OF HST SYSTEM…..306
OPERATION OF HST SYSTEM…..307
STEERING AND BRAKE CONTROL SYSTEM…..309
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM…..309
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM…..310
HST CONTROL SYSTEM…..311
HST CONTROL SYSTEM DIAGRAM…..311
GEAR SHIFT CONTROL FUNCTION…..312
ENGINE LOW SPEED MATCHING CONTROL FUNCTION…..316
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION…..317
DECELERATION AND BRAKE CONTROL FUNCTION…..319
GEAR SHIFT CONTROL FUNCTION BY LOAD…..321
TURN CONTROL FUNCTION…..322
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION…..323
PARKING BRAKE CONTROL SYSTEM…..324
PARKING BRAKE CONTROL SYSTEM DIAGRAM…..324
FUNCTION OF PARKING BRAKE CONTROL SYSTEM…..325
OPERATION OF PARKING BRAKE CONTROL SYSTEM…..326
COMPONENT PARTS OF POWER TRAIN SYSTEM…..327
HST PUMP…..327
HST CHARGE PUMP…..344
HST MOTOR…..345
FINAL DRIVE…..357
ELECTRIC STEERING CONTROL LEVER…..361
WORK EQUIPMENT SYSTEM…..363
WORK EQUIPMENT CONTROL…..363
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM…..363
FUNCTION OF WORK EQUIPMENT CONTROL…..365
LAYOUT DRAWING OF FRONT WORK EQUIPMENT…..367
LAYOUT OF FIXED MULTI-SHANK RIPPER…..368
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…..369
RIPPER PPC VALVE…..369
5-PORT VALVE OF EPC AND SOLENOID…..373
PILOT CIRCUIT ACCUMULATOR…..380
ANGLE CONTROL EPC VALVE…..381
PISTON VALVE…..384
ELECTRIC BLADE CONTROL LEVER…..385
ICT SYSTEM…..387
LAYOUT DRAWING OF ICT SYSTEM…..387
ICT CONTROL SYSTEM DIAGRAM…..389
BLADE CONTROL SYSTEM…..391
FUNCTION OF BLADE CONTROL SYSTEM…..392
LEVELING MODE SYSTEM DIAGRAM…..394
FUNCTION OF LEVELING MODE…..396
OPERATION OF LEVELING MODE…..397
DOZING MODE SYSTEM DIAGRAM…..398
FUNCTION OF DOZING MODE…..399
OPERATION OF DOZING MODE…..400
SMOOTH START SYSTEM…..401
SMOOTH START SYSTEM DIAGRAM…..401
FUNCTION OF SMOOTH START SYSTEM…..402
OPERATION OF SMOOTH START SYSTEM…..403
SLIP CONTROL SYSTEM…..404
SLIP CONTROL SYSTEM DIAGRAM…..404
FUNCTION OF SLIP CONTROL SYSTEM…..405
OPERATION OF SLIP CONTROL SYSTEM…..406
ASSIST CONTROL SYSTEM…..407
ASSIST CONTROL SYSTEM DIAGRAM…..407
FUNCTION OF ASSIST CONTROL SYSTEM…..408
OPERATION OF ASSIST CONTROL SYSTEM…..409
HST SPEED RANGE CONTROL SYSTEM…..410
HST SPEED RANGE CONTROL SYSTEM DIAGRAM…..410
FUNCTION OF HST SPEED RANGE CONTROL SYSTEM…..411
OPERATION OF HST SPEED RANGE CONTROL SYSTEM…..412
COMPONENT PARTS OF ICT SYSTEM…..413
ICT SENSOR CONTROLLER…..413
CONTROL BOX…..417
GNSS RECEIVER…..419
GNSS ANTENNA…..423
IMU SENSOR…..424
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER…..428
STROKE SENSOR FOR BLADE TILT CYLINDER…..431
STROKE SENSOR FOR BLADE ANGLE CYLINDER…..433
UNDERCARRIAGE AND FRAME…..435
MAIN FRAME…..435
STRUCTURE OF MAIN FRAME…..435
TRACK FRAME AND IDLER CUSHION…..436
STRUCTURE OF TRACK FRAME AND IDLER CUSHION…..436
FUNCTION OF TRACK FRAME AND IDLER CUSHION…..438
WORK EQUIPMENT…..439
STRUCTURE OF FRONT WORK EQUIPMENT…..439
STRUCTURE OF FIXED MULTI-SHANK RIPPER…..440
CAB AND ITS ATTACHMENTS…..441
ROPS CAB…..441
STRUCTURE OF ROPS CAB…..441
FUNCTION OF ROPS CAB…..442
CAB MOUNT…..443
STRUCTURE OF CAB MOUNT…..443
FUNCTION OF CAB MOUNT…..444
20 STANDARD VALUE TABLE…..445
CONTENTS…..446
ABBREVIATION LIST…..447
STANDARD VALUE TABLE FOR ENGINE…..453
STANDARD VALUE TABLE FOR ENGINE: D37EXI-24…..453
STANDARD VALUE TABLE FOR ENGINE: D37PXI-24…..456
STANDARD VALUE TABLE FOR ENGINE: D39EXI-24…..459
STANDARD VALUE TABLE FOR ENGINE: D39PXI-24…..462
STANDARD VALUE TABLE FOR MACHINE…..465
STANDARD VALUE TABLE FOR MACHINE: D37EXI-24…..465
STANDARD VALUE TABLE FOR MACHINE: D37PXI-24…..482
STANDARD VALUE TABLE FOR MACHINE: D39EXI-24…..497
STANDARD VALUE TABLE FOR MACHINE: D39PXI-24…..514
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE…..529
30 TESTING AND ADJUSTING…..531
CONTENTS…..532
ABBREVIATION LIST…..536
RELATED INFORMATION ON TESTING AND ADJUSTING…..542
TOOLS FOR TESTING AND ADJUSTING…..542
SKETCH OF TOOLS FOR TESTING AND ADJUSTING…..549
ENGINE AND COOLING SYSTEM…..552
TEST ENGINE SPEED…..552
METHOD FOR TESTING ENGINE SPEED…..552
TEST EXHAUST GAS COLOR…..554
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER…..554
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER…..555
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE…..556
METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE…..556
TEST AND ADJUST VALVE CLEARANCE…..558
METHOD FOR TESTING VALVE CLEARANCE…..558
METHOD FOR ADJUSTING VALVE CLEARANCE…..559
TEST COMPRESSION PRESSURE…..560
METHOD FOR TESTING COMPRESSION PRESSURE…..560
TEST BLOWBY PRESSURE…..563
METHOD FOR TESTING BLOWBY PRESSURE…..563
TEST ENGINE OIL PRESSURE…..565
METHOD FOR TESTING ENGINE OIL PRESSURE…..565
TEST FUEL PRESSURE…..567
METHOD FOR TESTING FUEL PRESSURE…..567
TEST FUEL RETURN RATE AND LEAKAGE…..569
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE…..570
BLEEDING AIR FROM FUEL SYSTEM…..574
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM…..574
TEST FUEL CIRCUIT FOR LEAKAGE…..576
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…..576
HANDLE CYLINDER CUT-OUT MODE OPERATION…..578
HANDLE NO-INJECTION CRANKING OPERATION…..579
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…..580
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…..580
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…..581
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…..581
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS…..582
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS…..582
TEST ALTERNATOR BELT…..583
METHOD FOR TESTING ALTERNATOR BELT…..583
TEST AUTOMATIC TENSIONER…..584
METHOD FOR TESTING AUTOMATIC TENSIONER…..584
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER…..586
METHOD FOR WRITING INJECTOR COMPENSATION VALUE…..586
TEST SCR RELATED FUNCTIONS…..592
TEST AdBlue/DEF PUMP RAISED PRESSURE…..596
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR…..599
TEST AdBlue/DEF LINE HEATER RELAY 1…..604
TEST AdBlue/DEF LINE HEATER RELAY 2…..607
TEST AdBlue/DEF PUMP HEATER RELAY…..610
TEST AdBlue/DEF TANK HEATER VALVE…..614
TEST DENITRATION EFFICIENCY OF SCR…..618
CLEAN AdBlue/DEF TANK…..621
METHOD FOR CLEANING AdBlue/DEF TANK…..621
CLEAN AdBlue/DEF TANK MOUNTING PORTION…..626
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION…..626
POWER TRAIN…..627
TEST AND ADJUST HST OIL PRESSURE…..627
METHOD FOR TESTING HST OIL PRESSURE…..627
METHOD FOR ADJUSTING HST OIL PRESSURE…..630
BLEED AIR FROM HST PUMP…..632
METHOD FOR BLEEDING AIR FROM HST PUMP…..632
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP…..632
TEST OUTLET PRESSURE OF SOLENOID VALVE…..634
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…..634
TEST TRAVEL DEVIATION…..639
METHOD FOR TESTING TRAVEL DEVIATION…..639
TEST BRAKE PERFORMANCE SIMPLY…..641
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY…..641
TEST AND ADJUST DECELERATION/BRAKE PEDAL…..642
METHOD FOR TESTING DECELERATION/BRAKE PEDAL…..642
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL…..644
ADJUST PARKING BRAKE LEVER…..646
METHOD FOR ADJUSTING PARKING BRAKE LEVER…..646
MOVE MACHINE WHEN IT CANNOT TRAVEL…..648
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM…..648
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT…..650
UNDERCARRIAGE AND FRAME…..652
ADJUST IDLER CLEARANCE…..652
METHOD FOR ADJUSTING IDLER CLEARANCE…..652
TESTING SPROCKET WEAR…..653
METHOD FOR TESTING SPROCKET WEAR…..653
TEST AND ADJUST TRACK TENSION…..654
METHOD FOR TESTING TRACK TENSION…..654
METHOD FOR ADJUSTING TRACK TENSION…..654
HYDRAULIC SYSTEM…..656
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM…..656
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…..656
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES…..657
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES…..657
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES…..658
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT…..660
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT…..660
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT…..661
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE…..662
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE…..662
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…..664
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…..664
TEST COOLING FAN SPEED…..665
METHOD FOR TESTING COOLING FAN SPEED…..665
TEST COOLING FAN CIRCUIT OIL PRESSURE…..666
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE…..666
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…..668
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER…..668
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER…..668
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER…..669
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…..670
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…..670
BLEED AIR FROM WORK EQUIPMENT CYLINDERS…..672
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS…..672
WORK EQUIPMENT…..673
ADJUST WORK EQUIPMENT LOCK LEVER…..673
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER…..673
ELECTRICAL SYSTEM…..675
SET AND OPERATE MACHINE MONITOR…..675
OPERATOR MODE…..679
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN…..679
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…..679
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)…..680
CHECKING FUNCTION OF SERVICE METER…..680
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD…..680
SERVICE MODE…..683
METHOD FOR OPERATING SERVICE MODE…..683
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…..685
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…..691
ABNORMALITY RECORD MENU…..702
METHOD FOR CONFIRMING MAINTENANCE RECORD…..706
METHOD FOR OPERATING MAINTENANCE MODE SETTING…..707
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…..711
DEFAULT MENU…..712
DIAGNOSTIC TESTS MENU…..719
ADJUSTMENT MENU…..727
METHOD FOR PERFORMING NO-INJECTION CRANKING…..796
KOMTRAX SETTINGS MENU…..799
METHOD FOR DISPLAYING SERVICE MESSAGE…..801
METHOD FOR STARTING UP KOMTRAX TERMINAL…..803
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED…..808
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED…..808
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED…..814
ADJUST REARVIEW CAMERA ANGLE…..816
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE…..816
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER…..817
HANDLE BATTERY DISCONNECT SWITCH…..818
TEST DIODES…..819
METHOD FOR TESTING DIODE USING DIGITAL TESTER…..819
METHOD FOR TESTING DIODE USING ANALOG TESTER…..819
ICT SYSTEM…..820
SET AND OPERATE CONTROL BOX…..820
TEST AND ADJUST ICT RELATED DEVICES…..820
CALIBRATE BLADE EDGE POSITION…..823
METHOD FOR OPERATING BLADE CALIBRATION MENU (PITCH ROD CALIBRATION)…..824
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A)…..826
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B)…..831
CALIBRATE IMU SENSOR…..845
METHOD FOR CALIBRATING IMU SENSOR…..845
RESET CYLINDER STROKE END…..852
RESET LIFT CYLINDER STROKE END…..852
RESET TILT CYLINDER STROKE END…..853
RESET ANGLE CYLINDER STROKE END…..853
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE…..855
CHECK BLADE ELEVATION, ADJUST…..857
CHECK BLADE ELEVATION…..857
ADJUST BLADE ELEVATION…..859
TEST STROKE SENSOR FOR LIFT CYLINDER…..861
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER…..861
TEST STROKE SENSOR FOR TILT CYLINDER…..863
METHOD FOR TESTING STROKE SENSOR FOR TILT CYLINDER…..863
TEST STROKE SENSOR FOR ANGLE CYLINDER…..865
METHOD FOR TESTING STROKE SENSOR FOR ANGLE CYLINDER…..865
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER…..867
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER…..867
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER…..868
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED…..869
METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED…..869
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED…..872
Pm CLINIC…..875
Pm CLINIC SERVICE…..875
Pm CLINIC CHECK SHEET: D37EXI-24…..877
Pm CLINIC CHECK SHEET: D37PXI-24…..885
Pm CLINIC CHECK SHEET: D39EXI-24…..893
Pm CLINIC CHECK SHEET: D39PXI-24…..900
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37EXI-24…..907
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37PXI-24…..914
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39EXI-24…..921
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39PXI-24…..928
40 TROUBLESHOOTING…..937
CONTENTS…..938
ABBREVIATION LIST…..949
RELATED INFORMATION ON TROUBLESHOOTING…..955
GENERAL TROUBLESHOOTING POINTS…..955
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…..956
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..968
CHECKS BEFORE TROUBLESHOOTING…..970
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…..972
WALK-AROUND CHECK…..972
TESTING IN ACCORDANCE WITH TESTING PROCEDURE…..974
CHECK FUEL LEVEL AND TYPE…..974
CHECK IMPURE INGREDIENT IN FUEL…..974
CHECK AdBule/DEF LEVEL AND TYPE…..975
CHECK FUEL PREFILTER…..975
CHECK MAIN FILTER…..977
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE…..979
CHECK COOLANT LEVEL (RESERVOIR TANK)…..980
CHECK CLOGGING OF AIR CLEANER…..980
CLEAN OUTER ELEMENT…..981
REPLACE ELEMENT…..982
CHECK HYDRAULIC OIL LEVEL…..983
CHECK HYDRAULIC OIL STRAINER…..984
CHECK OIL LEVEL IN FINAL DRIVE CASE…..988
BLEED AIR FROM FUEL SYSTEM…..988
BLEED AIR FROM HYDRAULIC SYSTEM…..988
METHOD FOR CHECKING ELECTRIC EQUIPMENT…..988
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…..995
PROCEDURE FOR TROUBLESHOOTING…..1002
SYMPTOM AND TROUBLESHOOTING NUMBERS…..1005
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…..1010
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…..1012
CONNECTORS LIST AND LAYOUT…..1015
CONNECTOR CONTACT IDENTIFICATION…..1032
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…..1072
FUSE LOCATION TABLE…..1078
PRECAUTIONS FOR REPLACING KDOC…..1082
FAILURE CODES TABLE…..1083
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…..1102
FAILURE CODE [6091NX]…..1102
FAILURE CODE [989L00]…..1104
FAILURE CODE [989M00]…..1105
FAILURE CODE [989N00]…..1106
FAILURE CODE [A1U0N3]…..1107
FAILURE CODE [A1U0N4]…..1109
FAILURE CODE [A900FR]…..1111
FAILURE CODE [A900N6]…..1112
FAILURE CODE [A900NY]…..1113
FAILURE CODE [AA10NX]…..1114
FAILURE CODE [AB00KE]…..1116
FAILURE CODE [AQ10MB]…..1118
FAILURE CODE [AQ10N3]…..1120
FAILURE CODE [AS00R2]…..1121
FAILURE CODE [AS00R3]…..1122
FAILURE CODE [AS00R4]…..1123
FAILURE CODE [AS00R5]…..1124
FAILURE CODE [AS00R6]…..1125
FAILURE CODE [AS00ZK]…..1126
FAILURE CODE [AS10KM]…..1127
FAILURE CODE [AS10NR]…..1128
FAILURE CODE [AS10NT]…..1129
FAILURE CODE [AU10QA]…..1130
FAILURE CODE [B@BAZG]…..1131
FAILURE CODE [B@BCNS]…..1132
FAILURE CODE [B@CRNS]…..1133
FAILURE CODE [B@CRZG]…..1134
FAILURE CODE [CA115]…..1135
FAILURE CODE [CA122]…..1136
FAILURE CODE [CA123]…..1138
FAILURE CODE [CA131]…..1140
FAILURE CODE [CA132]…..1142
FAILURE CODE [CA144]…..1144
FAILURE CODE [CA145]…..1146
FAILURE CODE [CA153]…..1148
FAILURE CODE [CA154]…..1151
FAILURE CODE [CA187]…..1154
FAILURE CODE [CA221]…..1156
FAILURE CODE [CA222]…..1158
FAILURE CODE [CA227]…..1160
FAILURE CODE [CA234]…..1161
FAILURE CODE [CA238]…..1162
FAILURE CODE [CA239]…..1164
FAILURE CODE [CA249]…..1166
FAILURE CODE [CA256]…..1168
FAILURE CODE [CA271]…..1170
FAILURE CODE [CA272]…..1172
FAILURE CODE [CA322]…..1174
FAILURE CODE [CA324]…..1176
FAILURE CODE [CA331]…..1178
FAILURE CODE [CA332]…..1180
FAILURE CODE [CA343]…..1182
FAILURE CODE [CA351]…..1183
FAILURE CODE [CA352]…..1184
FAILURE CODE [CA356]…..1187
FAILURE CODE [CA357]…..1189
FAILURE CODE [CA386]…..1191
FAILURE CODE [CA435]…..1192
FAILURE CODE [CA441]…..1194
FAILURE CODE [CA442]…..1196
FAILURE CODE [CA449]…..1197
FAILURE CODE [CA451]…..1198
FAILURE CODE [CA452]…..1200
FAILURE CODE [CA515]…..1202
FAILURE CODE [CA516]…..1204
FAILURE CODE [CA553]…..1206
FAILURE CODE [CA555]…..1207
FAILURE CODE [CA556]…..1208
FAILURE CODE [CA559]…..1209
FAILURE CODE [CA689]…..1213
FAILURE CODE [CA691]…..1215
FAILURE CODE [CA692]…..1217
FAILURE CODE [CA697]…..1219
FAILURE CODE [CA698]…..1220
FAILURE CODE [CA731]…..1221
FAILURE CODE [CA778]…..1223
FAILURE CODE [CA1117]…..1228
FAILURE CODE [CA1664]…..1229
FAILURE CODE [CA1669]…..1231
FAILURE CODE [CA1673]…..1232
FAILURE CODE [CA1677]…..1233
FAILURE CODE [CA1678]…..1234
FAILURE CODE [CA1682]…..1235
FAILURE CODE [CA1683]…..1240
FAILURE CODE [CA1684]…..1242
FAILURE CODE [CA1686]…..1244
FAILURE CODE [CA1691]…..1245
FAILURE CODE [CA1694]…..1247
FAILURE CODE [CA1695]…..1249
FAILURE CODE [CA1696]…..1250
FAILURE CODE [CA1712]…..1252
FAILURE CODE [CA1713]…..1255
FAILURE CODE [CA1714]…..1257
FAILURE CODE [CA1715]…..1258
FAILURE CODE [CA1776]…..1259
FAILURE CODE [CA1777]…..1262
FAILURE CODE [CA1843]…..1265
FAILURE CODE [CA1844]…..1267
FAILURE CODE [CA1885]…..1270
FAILURE CODE [CA1887]…..1272
FAILURE CODE [CA1896]…..1274
FAILURE CODE [CA1938]…..1275
FAILURE CODE [CA1942]…..1277
FAILURE CODE [CA1961]…..1278
FAILURE CODE [CA2185]…..1279
FAILURE CODE [CA2186]…..1281
FAILURE CODE [CA2249]…..1283
FAILURE CODE [CA2272]…..1284
FAILURE CODE [CA2311]…..1287
FAILURE CODE [CA2349]…..1288
FAILURE CODE [CA2353]…..1290
FAILURE CODE [CA2357]…..1292
FAILURE CODE [CA2555]…..1293
FAILURE CODE [CA2556]…..1295
FAILURE CODE [CA2636]…..1297
FAILURE CODE [CA2637]…..1300
FAILURE CODE [CA2765]…..1302
FAILURE CODE [CA2771]…..1303
FAILURE CODE [CA2976]…..1309
FAILURE CODE [CA3142]…..1311
FAILURE CODE [CA3143]…..1312
FAILURE CODE [CA3144]…..1313
FAILURE CODE [CA3146]…..1315
FAILURE CODE [CA3147]…..1316
FAILURE CODE [CA3148]…..1317
FAILURE CODE [CA3151]…..1319
FAILURE CODE [CA3165]…..1325
FAILURE CODE [CA3229]…..1327
FAILURE CODE [CA3231]…..1329
FAILURE CODE [CA3232]…..1331
FAILURE CODE [CA3235]…..1335
FAILURE CODE [CA3239]…..1337
FAILURE CODE [CA3241]…..1340
FAILURE CODE [CA3242]…..1343
FAILURE CODE [CA3251]…..1346
FAILURE CODE [CA3313]…..1348
FAILURE CODE [CA3314]…..1349
FAILURE CODE [CA3315]…..1350
FAILURE CODE [CA3419]…..1352
FAILURE CODE [CA3421]…..1354
FAILURE CODE [CA3497]…..1356
FAILURE CODE [CA3498]…..1357
FAILURE CODE [CA3543]…..1358
FAILURE CODE [CA3545]…..1364
FAILURE CODE [CA3547]…..1366
FAILURE CODE [CA3558]…..1367
FAILURE CODE [CA3559]…..1369
FAILURE CODE [CA3562]…..1371
FAILURE CODE [CA3563]…..1373
FAILURE CODE [CA3567]…..1376
FAILURE CODE [CA3568]…..1379
FAILURE CODE [CA3571]…..1384
FAILURE CODE [CA3572]…..1386
FAILURE CODE [CA3574]…..1388
FAILURE CODE [CA3575]…..1390
FAILURE CODE [CA3577]…..1392
FAILURE CODE [CA3578]…..1394
FAILURE CODE [CA3582]…..1396
FAILURE CODE [CA3583]…..1403
FAILURE CODE [CA3596]…..1405
FAILURE CODE [CA3649]…..1408
FAILURE CODE [CA3681]…..1410
FAILURE CODE [CA3682]…..1415
FAILURE CODE [CA3713]…..1420
FAILURE CODE [CA3717]…..1423
FAILURE CODE [CA3718]…..1424
FAILURE CODE [CA3724]…..1425
FAILURE CODE [CA3725]…..1426
FAILURE CODE [CA3748]…..1429
FAILURE CODE [CA3755]…..1432
FAILURE CODE [CA3866]…..1434
FAILURE CODE [CA3867]…..1437
FAILURE CODE [CA3868]…..1440
FAILURE CODE [CA3899]…..1444
FAILURE CODE [CA3911]…..1446
FAILURE CODE [CA3912]…..1450
FAILURE CODE [CA3918]…..1452
FAILURE CODE [CA3921]…..1454
FAILURE CODE [CA3928]…..1455
FAILURE CODE [CA3932]…..1456
FAILURE CODE [CA3933]…..1458
FAILURE CODE [CA3934]…..1460
FAILURE CODE [CA3935]…..1463
FAILURE CODE [CA3936]…..1465
FAILURE CODE [CA4152]…..1467
FAILURE CODE [CA4155]…..1471
FAILURE CODE [CA4156]…..1474
FAILURE CODE [CA4157]…..1477
FAILURE CODE [CA4159]…..1479
FAILURE CODE [CA4164]…..1480
FAILURE CODE [CA4165]…..1482
FAILURE CODE [CA4166]…..1484
FAILURE CODE [CA4168]…..1485
FAILURE CODE [CA4169]…..1488
FAILURE CODE [CA4171]…..1490
FAILURE CODE [CA4249]…..1494
FAILURE CODE [CA4251]…..1496
FAILURE CODE [CA4261]…..1498
FAILURE CODE [CA4277]…..1501
FAILURE CODE [CA4281]…..1504
FAILURE CODE [CA4459]…..1508
FAILURE CODE [CA4461]…..1511
FAILURE CODE [CA4533]…..1514
FAILURE CODE [CA4534]…..1515
FAILURE CODE [CA4731]…..1516
FAILURE CODE [CA4732]…..1517
FAILURE CODE [CA4739]…..1518
FAILURE CODE [CA4768]…..1519
FAILURE CODE [CA4769]…..1521
FAILURE CODE [CA4842]…..1524
FAILURE CODE [CA4952]…..1527
FAILURE CODE [CA5115]…..1529
FAILURE CODE [CA5179]…..1532
FAILURE CODE [CA5181]…..1534
FAILURE CODE [CA5271]…..1536
FAILURE CODE [CA5272]…..1538
FAILURE CODE [CA5273]…..1540
FAILURE CODE [CA5274]…..1542
FAILURE CODE [CA5275]…..1543
FAILURE CODE [CA5276]…..1545
FAILURE CODE [CA5277]…..1547
FAILURE CODE [CA5387]…..1548
FAILURE CODE [CA5388]…..1550
FAILURE CODE [CA5389]…..1552
FAILURE CODE [CA5391]…..1554
FAILURE CODE [CA5392]…..1558
FAILURE CODE [CA5393]…..1559
FAILURE CODE [CA5394]…..1562
FAILURE CODE [CA5395]…..1565
FAILURE CODE [CA5396]…..1568
FAILURE CODE [CA5631]…..1569
FAILURE CODE [CA5938]…..1571
FAILURE CODE [D130KA]…..1573
FAILURE CODE [D130KB]…..1575
FAILURE CODE [D130KY]…..1577
FAILURE CODE [D19JKZ]…..1579
FAILURE CODE [D811MC]…..1582
FAILURE CODE [D862KA]…..1583
FAILURE CODE [D8ALKA]…..1584
FAILURE CODE [D8ALKB]…..1586
FAILURE CODE [D8AQKR]…..1588
FAILURE CODE [DAF0MB]…..1591
FAILURE CODE [DAF0MC]…..1592
FAILURE CODE [DAF8KB]…..1593
FAILURE CODE [DAF9KQ]…..1595
FAILURE CODE [DAFGMC]…..1596
FAILURE CODE [DAFLKA]…..1597
FAILURE CODE [DAFLKB]…..1599
FAILURE CODE [DAFQKR]…..1601
FAILURE CODE [DAJ000]…..1605
FAILURE CODE [DAJ0KQ]…..1606
FAILURE CODE [DAJ0KT]…..1607
FAILURE CODE [DAJ0MC]…..1608
FAILURE CODE [DAJ1KK]…..1609
FAILURE CODE [DAJ2KK]…..1611
FAILURE CODE [DAJ5KK]…..1613
FAILURE CODE [DAJ6KK]…..1616
FAILURE CODE [DAJLKA]…..1618
FAILURE CODE [DAJLKB]…..1620
FAILURE CODE [DAJPMA]…..1622
FAILURE CODE [DAJQKR]…..1623
FAILURE CODE [DAJRKR]…..1627
FAILURE CODE [DB2QKR]…..1631
FAILURE CODE [DB2RKR]…..1635
FAILURE CODE [DBR0KT]…..1639
FAILURE CODE [DBR0MC]…..1640
FAILURE CODE [DBR1KK]…..1641
FAILURE CODE [DBR2KK]…..1644
FAILURE CODE [DBR5KK]…..1647
FAILURE CODE [DBRLKA]…..1649
FAILURE CODE [DBRLKB]…..1651
FAILURE CODE [DBRPMA]…..1653
FAILURE CODE [DBRQKR]…..1654
FAILURE CODE [DBRRKR]…..1658
FAILURE CODE [DBTSKR]…..1662
FAILURE CODE [DBUTKA]…..1664
FAILURE CODE [DD12KA]…..1665
FAILURE CODE [DD12KB]…..1667
FAILURE CODE [DD13KA]…..1669
FAILURE CODE [DD13KB]…..1671
FAILURE CODE [DD14KA]…..1673
FAILURE CODE [DD14KB]…..1675
FAILURE CODE [DDKAKA]…..1677
FAILURE CODE [DDKAKB]…..1679
FAILURE CODE [DDKFL4]…..1681
FAILURE CODE [DDKGL4]…..1683
FAILURE CODE [DDKHKA]…..1685
FAILURE CODE [DDKHKB]…..1687
FAILURE CODE [DDNLKA]…..1689
FAILURE CODE [DDNLKB]…..1691
FAILURE CODE [DDP6KA]…..1693
FAILURE CODE [DDP6KB]…..1695
FAILURE CODE [DDP6MA]…..1697
FAILURE CODE [DDU1FS]…..1699
FAILURE CODE [DDU1KA]…..1701
FAILURE CODE [DDU1KY]…..1703
FAILURE CODE [DFA4KX]…..1705
FAILURE CODE [DFA4KZ]…..1706
FAILURE CODE [DFA4L8]…..1707
FAILURE CODE [DFA5KA]…..1708
FAILURE CODE [DFA5KB]…..1710
FAILURE CODE [DFA6KA]…..1712
FAILURE CODE [DFA6KB]…..1714
FAILURE CODE [DFA7KX]…..1716
FAILURE CODE [DFA7KZ]…..1717
FAILURE CODE [DFA7L8]…..1718
FAILURE CODE [DFA8KA]…..1719
FAILURE CODE [DFA8KB]…..1721
FAILURE CODE [DFA9KA]…..1723
FAILURE CODE [DFA9KB]…..1725
FAILURE CODE [DGS1KA]…..1727
FAILURE CODE [DGS1KX]…..1729
FAILURE CODE [DH21KA]…..1731
FAILURE CODE [DH21KB]…..1733
FAILURE CODE [DHA4KA]…..1734
FAILURE CODE [DHH7KA]…..1736
FAILURE CODE [DHH7KB]…..1738
FAILURE CODE [DHH8KA]…..1740
FAILURE CODE [DHH8KB]…..1742
FAILURE CODE [DHH9KA]…..1744
FAILURE CODE [DHH9KB]…..1746
FAILURE CODE [DHHAKA]…..1748
FAILURE CODE [DHHAKB]…..1750
FAILURE CODE [DK30KA]…..1752
FAILURE CODE [DK30KB]…..1754
FAILURE CODE [DK30KX]…..1756
FAILURE CODE [DK30KZ]…..1757
FAILURE CODE [DK30L8]…..1758
FAILURE CODE [DK31KA]…..1761
FAILURE CODE [DK31KB]…..1763
FAILURE CODE [DK40KA]…..1765
FAILURE CODE [DK40KB]…..1767
FAILURE CODE [DK55KX]…..1769
FAILURE CODE [DK55KZ]…..1770
FAILURE CODE [DK55L8]…..1771
FAILURE CODE [DK56KA]…..1773
FAILURE CODE [DK56KB]…..1775
FAILURE CODE [DK57KA]…..1777
FAILURE CODE [DK57KB]…..1779
FAILURE CODE [DK80KA]…..1781
FAILURE CODE [DKS0L8]…..1783
FAILURE CODE [DKS1KA]…..1784
FAILURE CODE [DKS1KB]…..1786
FAILURE CODE [DKS2KA]…..1787
FAILURE CODE [DKS2KB]…..1789
FAILURE CODE [DKS3KA]…..1790
FAILURE CODE [DKS3KB]…..1792
FAILURE CODE [DKS3MB]…..1793
FAILURE CODE [DKS4L8]…..1795
FAILURE CODE [DKS5KA]…..1796
FAILURE CODE [DKS5KB]…..1798
FAILURE CODE [DKS6KA]…..1799
FAILURE CODE [DKS6KB]…..1801
FAILURE CODE [DKS7MB]…..1802
FAILURE CODE [DKSCL8]…..1803
FAILURE CODE [DKSDKA]…..1804
FAILURE CODE [DKSDKB]…..1806
FAILURE CODE [DKSEKA]…..1807
FAILURE CODE [DKSEKB]…..1809
FAILURE CODE [DKSFKA]…..1810
FAILURE CODE [DKSFKB]…..1812
FAILURE CODE [DKSFMB]…..1813
FAILURE CODE [DLM0KX]…..1814
FAILURE CODE [DLM0MA]…..1815
FAILURE CODE [DLM1KA]…..1816
FAILURE CODE [DLM1KB]…..1818
FAILURE CODE [DLM1MA]…..1820
FAILURE CODE [DLM2KA]…..1821
FAILURE CODE [DLM2KB]…..1823
FAILURE CODE [DLM2MA]…..1825
FAILURE CODE [DLM3KA]…..1826
FAILURE CODE [DLM3KB]…..1828
FAILURE CODE [DLM3MB]…..1830
FAILURE CODE [DN21FS]…..1831
FAILURE CODE [DR21KX]…..1833
FAILURE CODE [DR31KX]…..1834
FAILURE CODE [DV20KB]…..1835
FAILURE CODE [DW4BKA]…..1837
FAILURE CODE [DW4BKB]…..1839
FAILURE CODE [DW4BKY]…..1841
FAILURE CODE [DW7BKA]…..1842
FAILURE CODE [DW7BKB]…..1844
FAILURE CODE [DW7EKA]…..1845
FAILURE CODE [DW7EKB]…..1848
FAILURE CODE [DW7EKY]…..1851
FAILURE CODE [DWN5KA]…..1853
FAILURE CODE [DWN5KB]…..1855
FAILURE CODE [DWN5KY]…..1856
FAILURE CODE [DXA4KA]…..1857
FAILURE CODE [DXA4KB]…..1859
FAILURE CODE [DXA4KY]…..1861
FAILURE CODE [DXA5KA]…..1862
FAILURE CODE [DXA5KB]…..1864
FAILURE CODE [DXA5KY]…..1866
FAILURE CODE [DXA6KA]…..1867
FAILURE CODE [DXA6KB]…..1869
FAILURE CODE [DXA6KY]…..1871
FAILURE CODE [DXA7KA]…..1872
FAILURE CODE [DXA7KB]…..1874
FAILURE CODE [DXA7KY]…..1876
FAILURE CODE [DXHRKA]…..1877
FAILURE CODE [DXHRKB]…..1879
FAILURE CODE [DXHRKY]…..1880
FAILURE CODE [DXHSKA]…..1881
FAILURE CODE [DXHSKB]…..1883
FAILURE CODE [DXHSKY]…..1884
FAILURE CODE [DXHTKA]…..1885
FAILURE CODE [DXHTKB]…..1887
FAILURE CODE [DXHTKY]…..1888
FAILURE CODE [DXHUKA]…..1889
FAILURE CODE [DXHUKB]…..1891
FAILURE CODE [DXHUKY]…..1892
FAILURE CODE [DXJ4KA]…..1893
FAILURE CODE [DXJ4KB]…..1895
FAILURE CODE [DXJCKA]…..1897
FAILURE CODE [DXJCKB]…..1899
FAILURE CODE [DXJCKY]…..1900
FAILURE CODE [DXJDKA]…..1901
FAILURE CODE [DXJDKB]…..1903
FAILURE CODE [DXJDKY]…..1904
FAILURE CODE [DXK1KA]…..1905
FAILURE CODE [DXK1KB]…..1907
FAILURE CODE [DXK1KY]…..1908
FAILURE CODE [DXK2KA]…..1909
FAILURE CODE [DXK2KB]…..1911
FAILURE CODE [DXK2KY]…..1912
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…..1913
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)…..1913
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK…..1920
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK…..1923
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP…..1925
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING…..1927
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP…..1930
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…..1931
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1932
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1933
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1934
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1935
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1936
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1937
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…..1938
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL…..1939
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…..1942
E-17 OPERATION MODE DOES NOT CHANGE…..1943
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN…..1944
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE…..1945
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…..1946
E-21 SERVICE MODE CANNOT BE SELECTED…..1947
E-22 WORK EQUIPMENT DOES NOT OPERATE…..1948
E-23 FOOT HEATER DOES NOT OPERATE…..1950
E-24 HORN DOES NOT SOUND…..1956
E-25 HORN DOES NOT STOP SOUNDING…..1958
E-26 BACKUP ALARM DOES NOT SOUND…..1959
E-27 BACKUP ALARM DOES NOT STOP SOUNDING…..1960
E-28 HEADLAMP DOES NOT LIGHT UP…..1961
E-29 REAR LAMP DOES NOT LIGHT UP…..1965
E-30 ALL WIPERS DO NOT OPERATE…..1968
E-31 FRONT WIPER DOES NOT OPERATE…..1970
E-32 REAR WIPER DOES NOT OPERATE…..1972
E-33 LEFT DOOR WIPER DOES NOT OPERATE…..1974
E-34 RIGHT DOOR WIPER DOES NOT OPERATE…..1978
E-35 FRONT WASHER DOES NOT OPERATE…..1982
E-36 REAR WASHER DOES NOT OPERATE…..1984
E-37 LEFT DOOR WASHER DOES NOT OPERATE…..1986
E-38 RIGHT DOOR WASHER DOES NOT OPERATE…..1988
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…..1990
E-40 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]…..1991
E-41 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]…..1995
E-42 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link…]…..2000
E-43 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]…..2001
E-44 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites…]…..2002
E-45 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!]…..2003
E-46 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]…..2005
E-47 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal]…..2006
E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble]…..2007
E-49 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize…]…..2008
E-50 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing]…..2009
E-51 CONTROL BOX DISPLAYS THE MESSAGE [Initializing…]…..2010
E-52 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS]…..2011
E-53 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization…]…..2012
E-54 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions…]…..2013
E-55 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing]…..2014
E-56 CONTROL BOX DISPLAYS [Out of design area…]…..2015
E-57 CONTROL BOX CAN NOT BE TURNED ON…..2016
E-58 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN…..2017
E-59 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE…..2018
E-60 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE…..2019
E-61 CONTROL BOX TOUCH PANEL DOES NOT RESPOND…..2020
E-62 CONTROL BOX TOUCH PANEL IS INACCURATE…..2021
E-63 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT…..2022
E-64 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)…..2023
E-65 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…..2025
E-66 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…..2026
E-67 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)…..2027
E-68 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE…..2028
E-69 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)…..2029
E-70 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH)…..2030
E-71 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)…..2031
E-72 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)…..2033
E-73 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…..2034
E-74 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE…..2035
E-75 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…..2037
E-76 WHEN PRESSING CUT/FILL LEVEL SWITCH (RAISE), THE DESIGN SURFACE DOES NOT RISE…..2039
E-77 WHEN PRESSING CUT/FILL LEVEL SWITCH (LOWER), THE DESIGN SURFACE DOES NOT LOWER…..2042
E-78 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT…..2045
E-79 WHEN REVERSE LEVELING MODE SWITCH IS PRESSED, BUZZER DOES NOT SOUND (DOES NOT SWITCH TO REVERSE LEVELING MODE)…..2047
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…..2050
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)…..2050
FAILURE MODE AND CAUSE TABLE…..2051
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE)…..2057
H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE)…..2059
H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)…..2061
H-4 TRAVEL SPEED OR POWER IS LOW…..2063
H-5 SPEED RANGE DOES NOT CHANGE…..2065
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS…..2066
H-7 MACHINE DEVIATES LARGELY…..2067
H-8 MACHINE DRIFT ON A SLOPE IS LARGE…..2070
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS…..2072
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR…..2074
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH…..2076
H-12 ALL WORK EQUIPMENT DO NOT OPERATE…..2078
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW…..2080
H-14 BLADE LIFT SPEED OR POWER IS LOW…..2081
H-15 BLADE TILT SPEED OR POWER IS LOW…..2083
H-16 BLADE ANGLE SPEED OR POWER IS LOW…..2084
H-17 TIME LAG OF BLADE LIFT IS LARGE…..2085
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE…..2086
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE…..2087
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE…..2088
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)…..2089
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN…..2091
TROUBLESHOOTING OF ENGINE (S-MODE)…..2092
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)…..2092
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION…..2093
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT…..2094
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)…..2095
S-4 ENGINE STARTABILITY IS POOR…..2096
S-5 ENGINE DOES NOT PICK UP SMOOTHLY…..2098
S-6 ENGINE STOPS DURING OPERATION…..2100
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE…..2102
S-8 ENGINE LACKS POWER…..2103
S-9 EXHAUST SMOKE IS BLACK…..2105
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE…..2107
S-11 OIL BECOMES CONTAMINATED QUICKLY…..2108
S-12 FUEL CONSUMPTION IS EXCESSIVE…..2109
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…..2110
S-14 OIL PRESSURE DROPS…..2111
S-15 FUEL MIXES INTO ENGINE OIL…..2112
S-16 WATER MIXES INTO ENGINE OIL (MILKY)…..2113
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…..2114
S-18 UNUSUAL NOISE IS HEARD…..2115
S-19 VIBRATION IS EXCESSIVE…..2117
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…..2118
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY…..2119
S-22 ACTIVE REGENERATION TAKES TIME…..2120
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…..2121
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE…..2122
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)…..2124
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)…..2125
50 DISASSEMBLY AND ASSEMBLY…..2127
CONTENTS…..2128
ABBREVIATION LIST…..2133
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…..2139
HOW TO READ THIS MANUAL…..2139
COATING MATERIALS LIST…..2141
SPECIAL TOOLS LIST…..2145
SKETCHES OF SPECIAL TOOLS…..2164
ENGINE AND COOLING SYSTEM…..2180
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…..2180
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY…..2180
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…..2184
REMOVE AND INSTALL INJECTOR ASSEMBLY…..2188
METHOD FOR REMOVING INJECTOR ASSEMBLY…..2188
METHOD FOR INSTALLING INJECTOR ASSEMBLY…..2191
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…..2197
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY…..2197
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…..2211
REMOVE AND INSTALL EGR VALVE ASSEMBLY…..2231
METHOD FOR REMOVING EGR VALVE ASSEMBLY…..2231
METHOD FOR INSTALLING EGR VALVE ASSEMBLY…..2232
REMOVE AND INSTALL EGR COOLER ASSEMBLY…..2234
METHOD FOR REMOVING EGR COOLER ASSEMBLY…..2234
METHOD FOR INSTALLING EGR COOLER ASSEMBLY…..2235
REMOVE AND INSTALL STARTER ASSEMBLY…..2238
METHOD FOR REMOVING STARTER ASSEMBLY…..2238
METHOD FOR INSTALLING STARTER ASSEMBLY…..2239
REMOVE AND INSTALL ALTERNATOR BELT…..2241
METHOD FOR REMOVING ALTERNATOR BELT…..2241
METHOD FOR INSTALLING ALTERNATOR BELT…..2242
REMOVE AND INSTALL AUTOMATIC TENSIONER…..2244
METHOD FOR REMOVING AUTOMATIC TENSIONER…..2244
METHOD FOR INSTALLING AUTOMATIC TENSIONER…..2244
REMOVE AND INSTALL RADIATOR ASSEMBLY…..2245
METHOD FOR REMOVING RADIATOR ASSEMBLY…..2245
METHOD FOR INSTALLING RADIATOR ASSEMBLY…..2248
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…..2252
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY…..2252
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY…..2254
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…..2257
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY…..2257
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY…..2259
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY…..2263
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY…..2263
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY…..2265
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY…..2267
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY…..2267
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY…..2268
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY…..2270
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY…..2270
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY…..2276
REMOVE AND INSTALL ENGINE FRONT OIL SEAL…..2284
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…..2284
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…..2285
REMOVE AND INSTALL ENGINE REAR OIL SEAL…..2287
METHOD FOR REMOVING ENGINE REAR OIL SEAL…..2287
METHOD FOR INSTALLING ENGINE REAR OIL SEAL…..2288
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…..2291
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY…..2291
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY…..2293
REMOVE AND INSTALL KDOC ASSEMBLY…..2297
METHOD FOR REMOVING KDOC ASSEMBLY…..2297
METHOD FOR INSTALLING KDOC ASSEMBLY…..2301
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY…..2308
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY…..2309
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY…..2318
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY…..2328
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY…..2328
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY…..2330
REMOVE AND INSTALL FUEL TANK ASSEMBLY…..2335
METHOD FOR REMOVING FUEL TANK ASSEMBLY…..2335
METHOD FOR INSTALLING FUEL TANK ASSEMBLY…..2338
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY…..2342
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY…..2342
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY…..2348
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…..2354
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…..2354
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…..2355
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR…..2358
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR…..2358
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR…..2359
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER…..2361
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER…..2361
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER…..2362
REMOVE AND INSTALL SCR ASSEMBLY…..2363
METHOD FOR REMOVING SCR ASSEMBLY…..2363
METHOD FOR INSTALLING SCR ASSEMBLY…..2367
REMOVE AND INSTALL KCCV ASSEMBLY…..2371
METHOD FOR REMOVING KCCV ASSEMBLY…..2371
METHOD FOR INSTALLING KCCV ASSEMBLY…..2372
REMOVE AND INSTALL TURBO CHARGER ASSEMBLY…..2373
METHOD FOR REMOVING TURBO CHARGER ASSEMBLY…..2373
METHOD FOR INSTALLING TURBO CHARGER ASSEMBLY…..2377
REMOVE AND INSTALL EXHAUST THROTTLE VALVE…..2382
METHOD FOR REMOVING EXHAUST THROTTLE VALVE…..2382
METHOD FOR INSTALLING EXHAUST THROTTLE VALVE…..2386
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE…..2392
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE…..2393
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE…..2397
REMOVE AND INSTALL AdBlue/DEF INJECTOR…..2405
METHOD FOR REMOVING AdBlue/DEF INJECTOR…..2405
METHOD FOR INSTALLING AdBlue/DEF INJECTOR…..2408
REMOVE AND INSTALL AdBlue/DEF PUMP…..2412
METHOD FOR REMOVING AdBlue/DEF PUMP…..2412
METHOD FOR INSTALLING AdBlue/DEF PUMP…..2415
REMOVE AND INSTALL AdBlue/DEF HOSE…..2418
METHOD FOR REMOVING AdBlue/DEF HOSE…..2418
METHOD FOR INSTALLING AdBlue/DEF HOSE…..2426
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…..2436
METHOD FOR REMOVING AIR CLEANER ASSEMBLY…..2436
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY…..2437
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY…..2439
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…..2439
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…..2440
POWER TRAIN…..2442
REMOVE AND INSTALL DAMPER ASSEMBLY…..2442
METHOD FOR REMOVING DAMPER ASSEMBLY…..2442
METHOD FOR INSTALLING DAMPER ASSEMBLY…..2443
REMOVE AND INSTALL HST PUMP ASSEMBLY…..2444
METHOD FOR REMOVING HST PUMP ASSEMBLY…..2444
METHOD FOR INSTALLING HST PUMP ASSEMBLY…..2447
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY…..2450
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY…..2450
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY…..2452
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY…..2454
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY…..2454
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY…..2459
UNDERCARRIAGE AND FRAME…..2469
REMOVE AND INSTALL IDLER AND RECOIL SPRING ASSEMBLY…..2469
METHOD FOR REMOVING IDLER AND RECOIL SPRING ASSEMBLY…..2469
METHOD FOR INSTALLING IDLER AND RECOIL SPRING ASSEMBLY…..2469
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…..2471
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…..2471
METHOD FOR ASSEMBLING IDLER ASSEMBLY…..2473
DISASSEMBLE AND ASSEMBLE RECOIL SPRING…..2477
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING…..2478
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY…..2479
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY…..2481
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…..2481
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY…..2483
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY…..2487
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…..2487
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY…..2488
SEPARATE AND CONNECT TRACK ASSEMBLY…..2491
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)…..2491
METHOD FOR CONNECTING TRACK ASSEMBLY…..2492
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY…..2494
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY…..2494
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY…..2494
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY…..2496
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY…..2497
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY…..2499
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY…..2512
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…..2513
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…..2514
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…..2529
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…..2531
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…..2532
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…..2540
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…..2541
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…..2543
HYDRAULIC SYSTEM…..2548
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…..2548
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY…..2548
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY…..2553
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…..2558
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY…..2558
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…..2560
WORK EQUIPMENT…..2563
REMOVE AND INSTALL BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER)…..2563
METHOD FOR REMOVING BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER)…..2563
METHOD FOR INSTALLING BLADE ASSEMBLY…..2565
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY…..2568
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY…..2568
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY…..2570
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2573
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2573
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2575
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2577
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2578
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2582
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2590
METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2590
METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2593
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2597
METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2597
METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2601
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2606
METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2606
METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2608
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2612
METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2612
METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2616
REMOVE AND INSTALL U-FRAME ASSEMBLY…..2622
METHOD FOR REMOVING U-FRAME ASSEMBLY…..2622
METHOD FOR INSTALLING U-FRAME ASSEMBLY…..2624
CAB AND ITS ATTACHMENTS…..2627
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY…..2627
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY…..2627
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY…..2633
REMOVE AND INSTALL WIPER ARM…..2640
METHOD FOR REMOVING WIPER ARM…..2640
METHOD FOR INSTALLING WIPER ARM…..2641
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)…..2643
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)…..2645
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)…..2645
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…..2651
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY…..2651
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY…..2657
REMOVE AND INSTALL OPERATOR'S SEAT…..2665
METHOD FOR REMOVING OPERATOR'S SEAT…..2665
METHOD FOR INSTALLING OPERATOR'S SEAT…..2666
REMOVE AND INSTALL SEAT BELT…..2667
METHOD FOR REMOVING SEAT BELT…..2667
METHOD FOR INSTALLING SEAT BELT…..2667
REMOVE AND INSTALL FOOT HEATER ASSEMBLY…..2669
METHOD FOR REMOVING FOOT HEATER ASSEMBLY…..2669
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY…..2671
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY…..2673
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY…..2673
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY…..2674
ELECTRICAL SYSTEM…..2675
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY…..2675
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…..2675
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…..2677
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY…..2681
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY…..2681
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY…..2682
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…..2683
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…..2683
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…..2684
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…..2686
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR…..2686
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR…..2688
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR…..2689
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR…..2689
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR…..2690
REMOVE AND INSTALL SCR TEMPERATURE SENSOR…..2692
METHOD FOR REMOVING SCR TEMPERATURE SENSOR…..2692
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR…..2694
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY…..2696
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY…..2696
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY…..2697
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY…..2698
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY…..2698
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY…..2698
REMOVE AND INSTALL CONTROL BOX…..2700
METHOD FOR REMOVING CONTROL BOX…..2700
METHOD FOR INSTALLING CONTROL BOX…..2701
REMOVE AND INSTALL GNSS RECEIVER…..2702
METHOD FOR REMOVING GNSS RECEIVER…..2702
METHOD FOR INSTALLING GNSS RECEIVER…..2702
REMOVE AND INSTALL GNSS ANTENNA…..2704
METHOD FOR REMOVING GNSS ANTENNA…..2704
METHOD FOR INSTALLING GNSS ANTENNA…..2705
REMOVE AND INSTALL IMU SENSOR…..2710
METHOD FOR REMOVING IMU SENSOR…..2710
METHOD FOR INSTALLING IMU SENSOR…..2711
60 MAINTENANCE STANDARD…..2715
CONTENTS…..2716
ABBREVIATION LIST…..2718
ENGINE AND COOLING SYSTEM…..2724
MAINTENANCE STANDARD OF ENGINE MOUNT…..2724
MAINTENANCE STANDARD OF DAMPER…..2725
MAINTENANCE STANDARD OF COOLING SYSTEM…..2726
MAINTENANCE STANDARD OF COOLING FAN MOTOR…..2728
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP…..2730
POWER TRAIN…..2731
MAINTENANCE STANDARD OF HST PUMP…..2731
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP…..2732
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP…..2733
MAINTENANCE STANDARD OF HST CHARGE PUMP…..2734
MAINTENANCE STANDARD OF HST MOTOR…..2736
MAINTENANCE STANDARD OF FINAL DRIVE…..2737
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D37EXI-24,D37PXI-24…..2739
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D39EXI-24,D39PXI-24…..2741
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D37EXI-24,D37PXI-24…..2743
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D39EXI-24,D39PXI-24…..2744
UNDERCARRIAGE AND FRAME…..2745
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION…..2745
MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D37EXI-24,D37PXI-24…..2750
MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D39EXI-24,D39PXI-24…..2752
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)…..2754
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)…..2756
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE…..2758
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE…..2760
MAINTENANCE STANDARD OF SINGLE SHOE…..2764
HYDRAULIC SYSTEM…..2765
MAINTENANCE STANDARD OF HYDRAULIC TANK…..2765
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP…..2766
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP…..2767
MAINTENANCE STANDARD OF CONTROL VALVE…..2769
MAINTENANCE STANDARD OF RIPPER PPC VALVE…..2776
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID…..2778
MAINTENANCE STANDARD OF EPC VALVE…..2779
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE…..2780
WORK EQUIPMENT…..2781
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT…..2781
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT…..2784
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER…..2785
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER…..2786
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER…..2787
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER…..2788
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER…..2789
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER…..2790
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER…..2791
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER…..2793
CAB AND ITS ATTACHMENTS…..2794
MAINTENANCE STANDARD OF CAB MOUNT…..2794
ELECTRICAL SYSTEM…..2795
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER…..2795
80 APPENDIX…..2797
CONTENTS…..2798
ABBREVIATION LIST…..2799
AIR CONDITIONER SYSTEM…..2805
PRECAUTIONS FOR REFRIGERANT…..2805
AIR CONDITIONER COMPONENT…..2806
SPECIFICATIONS OF AIR CONDITIONER…..2809
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE…..2810
OUTLINE OF REFRIGERATION CYCLE…..2811
COMPONENT PARTS OF AIR CONDITIONER SYSTEM…..2813
AIR CONDITIONER UNIT…..2813
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT…..2813
FUNCTION OF AIR CONDITIONER UNIT…..2814
COMPONENT PARTS OF AIR CONDITIONER UNIT…..2815
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT…..2815
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…..2815
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT…..2815
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…..2816
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…..2816
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…..2816
FUNCTION OF DUAL PRESSURE SWITCH…..2817
FUNCTION OF PRESSURE SWITCH…..2817
COMPRESSOR…..2818
STRUCTURE OF COMPRESSOR…..2818
SPECIFICATIONS OF COMPRESSOR…..2818
FUNCTION OF COMPRESSOR…..2818
CONDENSER…..2819
STRUCTURE OF CONDENSER…..2819
SPECIFICATIONS OF CONDENSER…..2819
FUNCTION OF CONDENSER…..2820
RECEIVER DRIER…..2821
STRUCTURE OF RECEIVER DRIER…..2821
SPECIFICATIONS OF RECEIVER DRIER…..2821
FUNCTION OF RECEIVER DRIER…..2821
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…..2823
CIRCUIT DIAGRAM OF AIR CONDITIONER…..2826
AIR CONDITIONER SYSTEM DIAGRAM…..2827
CONTROL FUNCTION OF AIR CONDITIONER…..2828
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS…..2829
TEST RELAYS…..2833
METHOD FOR TESTING RELAYS…..2833
AIR CONDITIONER TROUBLESHOOTING CHART 1…..2835
AIR CONDITIONER TROUBLESHOOTING CHART 2…..2836
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…..2839
A-1 TROUBLESHOOTING FOR CONDENSER FAN…..2841
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)…..2844
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)…..2848
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION…..2851
TROUBLESHOOTING USING GAUGE PRESSURE…..2855
CONNECTION OF SERVICE TOOL…..2857
METHOD FOR CONNECTING SERVICE TOOL…..2857
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS…..2858
HANDLE COMPRESSOR OIL…..2860
90 CIRCUIT DIAGRAMS…..2863
CONTENTS…..2864
ABBREVIATION LIST…..2865
HYDRAULIC CIRCUIT DIAGRAM…..2871
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…..2871
HYDRAULIC CIRCUIT DIAGRAM…..2875
ELECTRICAL CIRCUIT DIAGRAM…..2876
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM…..2876
ELECTRICAL CIRCUIT DIAGRAM (1/11)…..2880
ELECTRICAL CIRCUIT DIAGRAM (2/11)…..2881
ELECTRICAL CIRCUIT DIAGRAM (3/11)…..2882
ELECTRICAL CIRCUIT DIAGRAM (4/11)…..2883
ELECTRICAL CIRCUIT DIAGRAM (5/11)…..2884
ELECTRICAL CIRCUIT DIAGRAM (6/11)…..2885
ELECTRICAL CIRCUIT DIAGRAM (7/11)…..2886
ELECTRICAL CIRCUIT DIAGRAM (8/11)…..2887
ELECTRICAL CIRCUIT DIAGRAM (9/11)…..2888
ELECTRICAL CIRCUIT DIAGRAM (10/11)…..2889
ELECTRICAL CIRCUIT DIAGRAM (11/11)…..2890
INDEX…..2891
Komatsu Bulldozer D37EXi, D37PXi, D39EXi, D39PXi Repair Service Manuals