Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-07 – PDF DOWNLOAD

Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-07 – PDF DOWNLOAD

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Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-07 – PDF DOWNLOAD

Language : English
Pages : 3582
Downloadable : Yes
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Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-07 – PDF DOWNLOAD

SERIAL NUMBERS 100040 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

General precautions
If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation
and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
• Always wear the protective eyeglasses when hitting parts
with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, always
agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator’s
compartment Before starting work.
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work:
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible,
insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.

TABLE OF CONTENTS:

Komatsu D155AXi-8 Bulldozer Shop Manual SEN06582-07 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 26
FOREWORD, SAFETY, BASIC INFORMATION 32
HOW TO READ THE SHOP MANUAL 32
SAFETY NOTICE FOR OPERATION 34
PRECAUTIONS TO PREVENT FIRE 42
ACTIONS IF FIRE OCCURS 44
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 45
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 46
PRECAUTIONS FOR DEF 47
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 47
PRECAUTIONS FOR ADDING 47
PRECAUTIONS FOR STORING 47
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 47
THE OTHER PRECAUTIONS 47
STORE AdBlue/DEF 48
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 52
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 59
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 61
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 62
PRACTICAL USE OF KOMTRAX 63
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 65
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 66
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 68
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 72
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 76
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 78
HOW TO READ ELECTRICAL WIRE CODE 79
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 83
STANDARD TIGHTENING TORQUE TABLE 86
CONVERSION TABLE 93
01 SPECIFICATIONS 99
CONTENTS 100
ABBREVIATION LIST 101
SPECIFICATIONS 107
SPECIFICATION DRAWING 107
SPECIFICATION DRAWING: D155AXI-8 107
SPECIFICATIONS 109
SPECIFICATIONS: D155AXI-8 109
WEIGHT TABLE 116
WEIGHT TABLE: D155AXI-8 116
TABLE OF FUEL, COOLANT, AND LUBRICANTS 118
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATION LIST 124
UREA SCR SYSTEM 130
LAYOUT DRAWING OF UREA SCR SYSTEM 130
UREA SCR SYSTEM DIAGRAM 132
FUNCTION OF UREA SCR SYSTEM 133
FUNCTION OF AdBlue/DEF SYSTEM 133
INDUCEMENT STRATEGY 135
COMPONENT PARTS OF UREA SCR SYSTEM 149
AdBlue/DEF MIXING TUBE 149
SCR ASSEMBLY 150
AdBlue/DEF TANK 152
AdBlue/DEF PUMP 154
AdBlue/DEF INJECTOR 155
AdBlue/DEF HOSE 156
AdBlue/DEF TANK HEATING VALVE 157
BOOT-UP SYSTEM 158
SYSTEM OPERATING LAMP SYSTEM 158
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 158
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 158
BATTERY DISCONNECT SWITCH 160
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 160
FUNCTION OF BATTERY DISCONNECT SWITCH 160
ENGINE SYSTEM 162
LAYOUT DRAWING OF ENGINE SYSTEM 162
ENGINE CONTROL SYSTEM 164
LAYOUT OF ENGINE CONTROL SYSTEM 164
ENGINE CONTROL SYSTEM DIAGRAM 165
FUNCTION OF ENGINE CONTROL SYSTEM 166
AUTOMATIC IDLE STOP SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 167
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 167
COMPONENT PARTS OF ENGINE SYSTEM 170
DAMPER 170
VGT 172
EGR SYSTEM 176
EGR VALVE 179
EGR COOLER 181
KCCV SYSTEM 183
KCCV VENTILATOR 185
KDPF 188
COOLING SYSTEM 192
LAYOUT DRAWING OF COOLING SYSTEM 192
SPECIFICATIONS OF COOLING SYSTEM 193
COMPONENT PARTS OF COOLING SYSTEM 194
COOLING FAN PUMP 194
COOLING FAN MOTOR 203
HYDRAULIC OIL COOLER BYPASS VALVE 210
CONTROL SYSTEM 211
LAYOUT DRAWING OF CONTROL SYSTEM 211
MACHINE MONITOR SYSTEM 212
MACHINE MONITOR SYSTEM DIAGRAM 212
FUNCTION OF MACHINE MONITOR SYSTEM 212
KOMTRAX SYSTEM 215
KOMTRAX SYSTEM DIAGRAM 215
FUNCTION OF KOMTRAX SYSTEM 215
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
KOMTRAX TERMINAL 232
POWER TRAIN CONTROLLER 234
WORK EQUIPMENT CONTROLLER 238
ENGINE CONTROLLER 242
FUEL FEED PUMP 249
FUEL FEED PUMP SWITCH 250
HYDRAULIC SYSTEM 251
LAYOUT DRAWING OF HYDRAULIC SYSTEM 251
CLSS 252
STRUCTURE OF CLSS 252
FUNCTION OF CLSS 253
COMPONENT PARTS OF HYDRAULIC SYSTEM 255
HYDRAULIC TANK 255
WORK EQUIPMENT AND HSS PUMP 257
LS VALVE 263
PC VALVE 268
PC-EPC VALVE 274
CONTROL VALVE 277
POWER TRAIN SYSTEM 319
LAYOUT OF POWER TRAIN SYSTEM 319
OPERATION OF POWER TRAIN SYSTEM 322
TRANSMISSION, STEERING, AND BRAKE CONTROL 324
LAYOUT OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM PARTS 324
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL 325
PALM COMMAND CONTROL SYSTEM 327
PALM COMMAND CONTROL SYSTEM DIAGRAM 327
HSS SYSTEM 331
HSS SYSTEM DIAGRAM 331
FUNCTION OF HSS SYSTEM 332
CENTRALIZED PRESSURE PICKUP PORT 334
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT 334
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT 335
COMPONENT PARTS OF POWER TRAIN SYSTEM 336
UNIVERSAL JOINT 336
POWER TRAIN MOUNT 337
TORQUE CONVERTER AND PTO 339
TORQUE CONVERTER CONTROL VALVE 346
LOCKUP CLUTCH ECMV 347
STATOR CLUTCH ECMV 351
TRANSMISSION 354
TRANSMISSION ECMV 365
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 372
TRANSMISSION LUBRICATION RELIEF VALVE 374
BEVEL GEAR SHAFT, HSS, AND BRAKE 375
FINAL DRIVE 401
SCAVENGING PUMP 404
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 405
HSS MOTOR 407
ELECTRIC STEERING CONTROL LEVER 415
WORK EQUIPMENT SYSTEM 419
WORK EQUIPMENT CONTROL 419
LAYOUT OF WORK EQUIPMENT CONTROL 419
WORK EQUIPMENT CONTROL FUNCTION 420
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 421
LAYOUT OF VARIABLE GIANT RIPPER 422
LAYOUT OF VARIABLE MULTI-SHANK RIPPER 423
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 424
SELF-PRESSURE REDUCING VALVE 424
WORK EQUIPMENT LOCK SOLENOID VALVE 431
PILOT CIRCUIT ACCUMULATOR 433
QUICK DROP VALVE 434
PISTON VALVE 439
ELECTRIC BLADE CONTROL LEVER 440
RIPPER ELECTRIC LEVER 441
ICT SYSTEM 442
LAYOUT DRAWING OF ICT SYSTEM 442
ICT CONTROL SYSTEM DIAGRAM 444
BLADE CONTROL SYSTEM 446
FUNCTION OF BLADE CONTROL SYSTEM 446
LEVELING MODE SYSTEM DIAGRAM 448
FUNCTION OF LEVELING MODE 449
OPERATION OF LEVELING MODE 449
DOZING MODE SYSTEM DIAGRAM 450
FUNCTION OF DOZING MODE 450
OPERATION OF DOZING MODE 450
SMOOTH START SYSTEM 452
SMOOTH START SYSTEM DIAGRAM 452
FUNCTION OF SMOOTH START SYSTEM 452
OPERATION OF SMOOTH START SYSTEM 452
SLIP CONTROL SYSTEM 454
SLIP CONTROL SYSTEM DIAGRAM 454
FUNCTION OF SLIP CONTROL SYSTEM 454
OPERATION OF SLIP CONTROL SYSTEM 454
ASSIST CONTROL SYSTEM 455
ASSIST CONTROL SYSTEM DIAGRAM 455
FUNCTION OF ASSIST CONTROL SYSTEM 455
OPERATION OF ASSIST CONTROL SYSTEM 456
COMPONENT PARTS OF ICT SYSTEM 457
CONTROL BOX 457
GNSS RECEIVER 460
GNSS ANTENNA 464
IMU SENSOR 465
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER 468
RADIO CONTROL SYSTEM 471
LAYOUT DRAWING OF RADIO CONTROL SYSTEM 471
SPECIFICATIONS OF RADIO CONTROL SYSTEM 472
COMPONENT PARTS OF RADIO CONTROL SYSTEM 473
RADIO CONTROL TRANSMITTER 473
RADIO CONTROL RECEIVER 475
RADIO CONTROL CONTROLLER 476
UNDERCARRIAGE AND FRAME 480
MAIN FRAME 480
STRUCTURE OF MAIN FRAME 480
SUSPENSION 481
STRUCTURE OF SUSPENSION 481
FUNCTION OF SUSPENSION 483
TRACK FRAME AND IDLER CUSHION 484
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 484
SPECIFICATIONS OF TRACK FRAME AND IDLER CUSHION 485
FUNCTION OF TRACK FRAME AND IDLER CUSHION 485
WORK EQUIPMENT 486
STRUCTURE OF FRONT WORK EQUIPMENT 486
STRUCTURE OF CYLINDER STAY 488
STRUCTURE OF VARIABLE GIANT RIPPER 489
STRUCTURE OF VARIABLE MULTI-SHANK RIPPER 490
CAB AND ITS ATTACHMENTS 491
ROPS CAB 491
STRUCTURE OF ROPS CAB 491
FUNCTION OF ROPS CAB 491
CAB MOUNT 492
STRUCTURE OF CAB MOUNT 492
20 STANDARD VALUE TABLE 493
CONTENTS 494
ABBREVIATION LIST 495
STANDARD VALUE TABLE FOR ENGINE 501
STANDARD VALUE TABLE FOR ENGINE: D155AXI-8 501
STANDARD VALUE TABLE FOR MACHINE 506
STANDARD VALUE TABLE FOR MACHINE: D155AXI-8 506
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 527
STANDARD VALUE TABLE FOR ELECTRICAL 529
STANDARD VALUE TABLE FOR ELECTRICITY 529
30 TESTING AND ADJUSTING 539
CONTENTS 540
ABBREVIATION LIST 544
RELATED INFORMATION ON TESTING AND ADJUSTING 550
TOOLS FOR TESTING AND ADJUSTING 550
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 558
ENGINE AND COOLING SYSTEM 560
TEST ENGINE SPEED 560
METHOD FOR TESTING ENGINE SPEED 560
TEST BOOST PRESSURE 565
METHOD FOR TESTING BOOST PRESSURE 565
TEST EXHAUST GAS TEMPERATURE 567
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 567
TEST EXHAUST GAS COLOR 570
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 570
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 571
TEST AND ADJUST VALVE CLEARANCE 572
METHOD FOR TESTING VALVE CLEARANCE 572
METHOD FOR ADJUSTING VALVE CLEARANCE 573
TEST COMPRESSION PRESSURE 575
METHOD FOR TESTING COMPRESSION PRESSURE 575
TEST BLOWBY PRESSURE 578
METHOD FOR TESTING BLOWBY PRESSURE 578
TEST ENGINE OIL PRESSURE 580
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 580
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 580
TEST EGR VALVE AND VGT OIL PRESSURE 582
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 582
TEST FUEL PRESSURE 584
METHOD FOR TESTING FUEL PRESSURE 584
TEST FUEL RETURN RATE AND LEAKAGE 586
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 587
BLEED AIR FROM FUEL SYSTEM 591
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 591
TEST FUEL CIRCUIT FOR LEAKAGE 593
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 593
HANDLE CYLINDER CUT-OUT MODE OPERATION 595
HANDLE NO-INJECTION CRANKING OPERATION 596
CLEAN FUEL DOSER 597
METHOD FOR CLEANING FUEL DOSER 597
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 599
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 599
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 605
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 605
TEST SCR RELATED FUNCTIONS 606
TEST AdBlue/DEF PUMP RAISED PRESSURE 610
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 613
TEST AdBlue/DEF LINE HEATER RELAY 1 618
TEST AdBlue/DEF LINE HEATER RELAY 2 621
TEST AdBlue/DEF PUMP HEATER RELAY 624
TEST AdBlue/DEF TANK HEATER VALVE 627
TEST DENITRATION EFFICIENCY OF SCR 630
CLEAN AdBlue/DEF TANK 633
METHOD FOR CLEANING AdBlue/DEF TANK 634
ADJUST DECELERATOR PEDAL 639
METHOD FOR ADJUSTING DECELERATOR PEDAL 639
POWER TRAIN 642
TEST POWER TRAIN OIL PRESSURE 642
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 643
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 653
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 653
TEST BRAKE PERFORMANCE SIMPLY 654
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 654
TEST AND ADJUST BRAKE PEDAL 655
METHOD FOR TESTING BRAKE PEDAL 655
METHOD FOR ADJUSTING BRAKE PEDAL 656
ADJUST PARKING BRAKE LEVER 659
METHOD FOR ADJUSTING PARKING BRAKE LEVER 659
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL 661
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 661
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM 662
UNDERCARRIAGE AND FRAME 665
ADJUST IDLER CLEARANCE 665
METHOD FOR ADJUSTING IDLER CLEARANCE 665
TEST AND ADJUST TRACK TENSION 667
METHOD FOR TESTING TRACK TENSION 667
METHOD FOR ADJUSTING TRACK TENSION 667
HYDRAULIC SYSTEM 668
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 668
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 668
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 669
METHOD FOR TESTING WORK EQUIPMENT AND HSS OIL PRESSURES 669
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES 672
TEST OIL PRESSURE OF CONTROL CIRCUIT 674
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 674
TEST WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE 676
METHOD FOR TESTING WORK EQUIPMENT LOCK SOLENOID VALVE OUTPUT PRESSURE 676
TEST RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE 678
METHOD FOR TESTING RIPPER PIN PULLER SOLENOID VALVE OUTPUT PRESSURE 678
BLEED AIR FROM WORK EQUIPMENT AND HSS PUMP 680
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND HSS PUMP 680
TEST COOLING FAN SPEED 681
METHOD FOR TESTING COOLING FAN SPEED 681
TEST COOLING FAN CIRCUIT OIL PRESSURE 682
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 682
BLEED AIR FROM COOLING FAN PUMP 684
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP 684
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 685
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 685
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 685
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 686
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 687
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 687
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 689
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 689
OPERATION WHEN WORK EQUIPMENT IS NOT EFFECTIVE 690
METHOD FOR OPERATING WHEN WORK EQUIPMENT IS NOT EFFECTIVE 690
WORK EQUIPMENT 692
ADJUST WORK EQUIPMENT LOCK LEVER 692
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 692
CAB AND ITS ATTACHMENTS 694
TEST AND ADJUST OPERATOR’S CAB 694
METHOD FOR TESTING OPERATOR’S CAB 694
METHOD FOR ADJUSTING OPERATOR’S CAB 697
ELECTRICAL SYSTEM 699
SET AND OPERATE MACHINE MONITOR 699
OPERATOR MODE 703
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 703
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 703
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 704
CHECKING FUNCTION OF SERVICE METER 704
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 704
SERVICE MODE 707
METHOD FOR OPERATING SERVICE MODE 707
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 709
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 715
ABNORMALITY RECORD MENU 728
METHOD FOR CONFIRMING MAINTENANCE RECORD 732
METHOD FOR OPERATING MAINTENANCE MODE SETTING 733
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 737
DEFAULT MENU 738
DIAGNOSTIC TESTS MENU 746
ADJUSTMENT MENU 755
METHOD FOR PERFORMING NO-INJECTION CRANKING 839
KOMTRAX SETTINGS MENU 841
METHOD FOR DISPLAYING SERVICE MESSAGE 843
METHOD FOR STARTING UP KOMTRAX TERMINAL 845
ADJUST REARVIEW CAMERA ANGLE 850
ADJUST REARVIEW CAMERA ANGLE 850
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 851
HANDLE BATTERY DISCONNECT SWITCH 852
TEST DIODES 853
METHOD FOR TESTING DIODE USING DIGITAL TESTER 853
METHOD FOR TESTING DIODE USING ANALOG TESTER 853
ICT SYSTEM 854
SET AND OPERATE CONTROL BOX 854
TEST AND ADJUST ICT RELATED DEVICES (DUAL TILT) 855
CALIBRATE BLADE EDGE POSITION 860
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A) (DUAL TILT) 861
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B) (DUAL TILT) 865
CALIBRATE IMU SENSOR 880
METHOD FOR CALIBRATING IMU SENSOR 880
RESET CYLINDER STROKE END 884
RESET LIFT CYLINDER STROKE END 884
SET STANDARD ANGLE OF BLADE EDGE (DUAL TILT) 886
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE 888
CHECK BLADE ELEVATION, ADJUST 889
CHECK BLADE ELEVATION (DUAL TILT) (FOR OLD CONTROL BOX) 889
CHECK BLADE ELEVATION (DUAL TILT) (FOR NEW CONTROL BOX) 892
ADJUST BLADE ELEVATION (FOR OLD CONTROL BOX) 895
ADJUST BLADE ELEVATION (FOR NEW CONTROL BOX) 895
TEST STROKE SENSOR FOR LIFT CYLINDER 897
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER 897
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER 901
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER 901
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER 902
ADJUST WHEN WORK EQUIPMENT CONTROLLER IS REPLACED 903
METHOD FOR ADJUSTING WHEN WORK EQUIPMENT CONTROLLER IS REPLACED 903
ADJUST WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED (DUAL TILT) 906
RADIO CONTROL 911
ID SETUP 911
METHOD FOR SETTING RADIO CONTROL TRANSMITTER ID 911
METHOD FOR SETTING RADIO CONTROL RECEIVER ID 912
Pm CLINIC 915
Pm CLINIC SERVICE 915
Pm CLINIC CHECK SHEET: D155AXI-8 917
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D155AXI-8 931
40 TROUBLESHOOTING 935
CONTENTS 936
ABBREVIATION LIST 950
RELATED INFORMATION ON TROUBLESHOOTING 956
GENERAL TROUBLESHOOTING POINTS 956
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 957
SEQUENCE OF EVENTS IN TROUBLESHOOTING 969
TROUBLESHOOTING FOR RADIO CONTROL SYSTEM 971
CHECKS BEFORE TROUBLESHOOTING (SPECIFICATIONS OF RADIO CONTROL) 971
TEST OPERATING STATE OF RADIO CONTROL RECEIVER 972
TEST OPERATING STATE OF RADIO CONTROL TRANSMITTER 973
CHECKS BEFORE TROUBLESHOOTING 974
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 976
WALK-AROUND CHECK 976
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 978
FUEL – CHECK LEVEL AND TYPE 978
FUEL – CHECK FOR FOREIGN MATERIAL 978
CHECK AdBule/DEF LEVEL AND TYPE 979
FUEL PREFILTER – CHECK 979
MAIN FILTER – CHECK 981
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 982
CHECK COOLANT LEVEL (RESERVOIR TANK) 983
CHECK CLOGGING OF AIR CLEANER 984
OUTER ELEMENT – CLEAN 985
REPLACE ELEMENT 987
CHECK HYDRAULIC OIL LEVEL 987
CHECK HYDRAULIC OIL STRAINER 989
CHECK HYDRAULIC FILTER 989
CHECK OIL LEVEL IN POWER TRAIN CASE 990
CHECK POWER TRAIN STRAINER 992
CHECK POWER TRAIN FILTER 993
CHECK OIL LEVEL IN DAMPER CASE 993
CHECK OIL LEVEL IN FINAL DRIVE CASE 994
METHOD FOR CHECKING ELECTRIC EQUIPMENT 996
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1003
SYMPTOM AND TROUBLESHOOTING NUMBERS 1006
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1011
CONNECTORS LIST AND LAYOUT 1013
CONNECTOR CONTACT IDENTIFICATION 1032
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1072
FUSE LOCATION TABLE 1078
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1081
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1085
FAILURE CODES TABLE 1087
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1114
FAILURE CODE [1500L0] 1114
FAILURE CODE [15SAL1] 1115
FAILURE CODE [15SALH] 1117
FAILURE CODE [15SBL1] 1119
FAILURE CODE [15SBLH] 1121
FAILURE CODE [15SEL1] 1123
FAILURE CODE [15SELH] 1125
FAILURE CODE [15SFL1] 1127
FAILURE CODE [15SFLH] 1129
FAILURE CODE [15SGL1] 1131
FAILURE CODE [15SGLH] 1133
FAILURE CODE [15SJL1] 1135
FAILURE CODE [15SJLH] 1137
FAILURE CODE [1800MW] 1139
FAILURE CODE [2300NR] 1140
FAILURE CODE [2301L1] 1141
FAILURE CODE [2301LH] 1143
FAILURE CODE [2302L1] 1145
FAILURE CODE [2302LH] 1147
FAILURE CODE [7RFAKA] 1149
FAILURE CODE [7RFAKB] 1151
FAILURE CODE [7RFAKY] 1153
FAILURE CODE [8512KX] 1155
FAILURE CODE [8513KX] 1156
FAILURE CODE [8514KX] 1157
FAILURE CODE [8515KX] 1158
FAILURE CODE [8516KX] 1159
FAILURE CODE [8517KX] 1160
FAILURE CODE [8518KX] 1161
FAILURE CODE [8519KX] 1162
FAILURE CODE [851AKX] 1163
FAILURE CODE [851BKX] 1164
FAILURE CODE [851CKX] 1165
FAILURE CODE [851DKX] 1166
FAILURE CODE [851EKX] 1167
FAILURE CODE [851FKX] 1168
FAILURE CODE [851GKX] 1169
FAILURE CODE [851HKX] 1170
FAILURE CODE [851JKX] 1171
FAILURE CODE [851KKX] 1172
FAILURE CODE [851LKX] 1173
FAILURE CODE [851MKX] 1174
FAILURE CODE [851NKX] 1175
FAILURE CODE [8580MC] 1176
FAILURE CODE [8581KK] 1177
FAILURE CODE [8582KK] 1180
FAILURE CODE [858LKA] 1182
FAILURE CODE [858LKB] 1184
FAILURE CODE [858QKR] 1186
FAILURE CODE [858RKR] 1187
FAILURE CODE [879AKA] 1188
FAILURE CODE [879AKB] 1189
FAILURE CODE [879BKA] 1190
FAILURE CODE [879BKB] 1192
FAILURE CODE [879CKA] 1194
FAILURE CODE [879CKB] 1195
FAILURE CODE [879DKZ] 1196
FAILURE CODE [879EMC] 1198
FAILURE CODE [879FMC] 1199
FAILURE CODE [879GKX] 1200
FAILURE CODE [989L00] 1202
FAILURE CODE [989M00] 1203
FAILURE CODE [989N00] 1204
FAILURE CODE [A1U0N3] 1205
FAILURE CODE [A1U0N4] 1207
FAILURE CODE [AA10NX] 1209
FAILURE CODE [AB00KE] 1211
FAILURE CODE [AQ10N3] 1213
FAILURE CODE [AS00N3] 1215
FAILURE CODE [AS00R2] 1217
FAILURE CODE [AS00R3] 1218
FAILURE CODE [AS00R4] 1219
FAILURE CODE [AS00R5] 1220
FAILURE CODE [AS00R6] 1221
FAILURE CODE [AS00ZK] 1222
FAILURE CODE [AS10KM] 1223
FAILURE CODE [AS10NR] 1224
FAILURE CODE [AS10NT] 1225
FAILURE CODE [B@BAZG] 1226
FAILURE CODE [B@BCNS] 1227
FAILURE CODE [B@BCZK] 1228
FAILURE CODE [B@CENS] 1230
FAILURE CODE [B@HANS] 1231
FAILURE CODE [CA115] 1232
FAILURE CODE [CA122] 1233
FAILURE CODE [CA123] 1235
FAILURE CODE [CA131] 1237
FAILURE CODE [CA132] 1239
FAILURE CODE [CA135] 1241
FAILURE CODE [CA141] 1243
FAILURE CODE [CA144] 1245
FAILURE CODE [CA145] 1247
FAILURE CODE [CA153] 1249
FAILURE CODE [CA154] 1252
FAILURE CODE [CA187] 1255
FAILURE CODE [CA221] 1257
FAILURE CODE [CA222] 1259
FAILURE CODE [CA227] 1261
FAILURE CODE [CA234] 1262
FAILURE CODE [CA238] 1263
FAILURE CODE [CA239] 1265
FAILURE CODE [CA249] 1267
FAILURE CODE [CA256] 1269
FAILURE CODE [CA271] 1271
FAILURE CODE [CA272] 1273
FAILURE CODE [CA273] 1274
FAILURE CODE [CA274] 1276
FAILURE CODE [CA322] 1277
FAILURE CODE [CA323] 1279
FAILURE CODE [CA324] 1281
FAILURE CODE [CA325] 1283
FAILURE CODE [CA331] 1285
FAILURE CODE [CA332] 1287
FAILURE CODE [CA343] 1289
FAILURE CODE [CA351] 1290
FAILURE CODE [CA352] 1291
FAILURE CODE [CA356] 1294
FAILURE CODE [CA357] 1296
FAILURE CODE [CA386] 1299
FAILURE CODE [CA441] 1300
FAILURE CODE [CA442] 1303
FAILURE CODE [CA449] 1304
FAILURE CODE [CA451] 1305
FAILURE CODE [CA452] 1307
FAILURE CODE [CA515] 1309
FAILURE CODE [CA516] 1311
FAILURE CODE [CA553] 1313
FAILURE CODE [CA555] 1314
FAILURE CODE [CA556] 1315
FAILURE CODE [CA559] 1316
FAILURE CODE [CA595] 1321
FAILURE CODE [CA687] 1322
FAILURE CODE [CA689] 1324
FAILURE CODE [CA691] 1326
FAILURE CODE [CA692] 1328
FAILURE CODE [CA697] 1330
FAILURE CODE [CA698] 1331
FAILURE CODE [CA731] 1332
FAILURE CODE [CA778] 1333
FAILURE CODE [CA1117] 1336
FAILURE CODE [CA1664] 1337
FAILURE CODE [CA1669] 1340
FAILURE CODE [CA1673] 1341
FAILURE CODE [CA1677] 1342
FAILURE CODE [CA1678] 1343
FAILURE CODE [CA1682] 1344
FAILURE CODE [CA1683] 1346
FAILURE CODE [CA1684] 1348
FAILURE CODE [CA1686] 1350
FAILURE CODE [CA1691] 1351
FAILURE CODE [CA1694] 1354
FAILURE CODE [CA1695] 1356
FAILURE CODE [CA1696] 1357
FAILURE CODE [CA1712] 1359
FAILURE CODE [CA1713] 1362
FAILURE CODE [CA1714] 1364
FAILURE CODE [CA1715] 1365
FAILURE CODE [CA1776] 1366
FAILURE CODE [CA1777] 1369
FAILURE CODE [CA1843] 1372
FAILURE CODE [CA1844] 1374
FAILURE CODE [CA1879] 1377
FAILURE CODE [CA1881] 1380
FAILURE CODE [CA1883] 1382
FAILURE CODE [CA1885] 1386
FAILURE CODE [CA1887] 1388
FAILURE CODE [CA1921] 1390
FAILURE CODE [CA1922] 1393
FAILURE CODE [CA1923] 1398
FAILURE CODE [CA1924] 1400
FAILURE CODE [CA1925] 1402
FAILURE CODE [CA1927] 1404
FAILURE CODE [CA1928] 1406
FAILURE CODE [CA1942] 1408
FAILURE CODE [CA1963] 1409
FAILURE CODE [CA1977] 1412
FAILURE CODE [CA1993] 1415
FAILURE CODE [CA2185] 1418
FAILURE CODE [CA2186] 1420
FAILURE CODE [CA2249] 1422
FAILURE CODE [CA2265] 1423
FAILURE CODE [CA2266] 1425
FAILURE CODE [CA2271] 1428
FAILURE CODE [CA2272] 1430
FAILURE CODE [CA2349] 1432
FAILURE CODE [CA2353] 1434
FAILURE CODE [CA2357] 1436
FAILURE CODE [CA2381] 1437
FAILURE CODE [CA2382] 1439
FAILURE CODE [CA2383] 1441
FAILURE CODE [CA2386] 1443
FAILURE CODE [CA2387] 1445
FAILURE CODE [CA2555] 1446
FAILURE CODE [CA2556] 1449
FAILURE CODE [CA2637] 1451
FAILURE CODE [CA2639] 1453
FAILURE CODE [CA2732] 1456
FAILURE CODE [CA2733] 1458
FAILURE CODE [CA2741] 1460
FAILURE CODE [CA2765] 1461
FAILURE CODE [CA2771] 1462
FAILURE CODE [CA2777] 1468
FAILURE CODE [CA2878] 1471
FAILURE CODE [CA2881] 1474
FAILURE CODE [CA2976] 1477
FAILURE CODE [CA3133] 1479
FAILURE CODE [CA3134] 1481
FAILURE CODE [CA3135] 1483
FAILURE CODE [CA3142] 1487
FAILURE CODE [CA3143] 1488
FAILURE CODE [CA3144] 1489
FAILURE CODE [CA3146] 1491
FAILURE CODE [CA3147] 1492
FAILURE CODE [CA3148] 1493
FAILURE CODE [CA3151] 1495
FAILURE CODE [CA3165] 1501
FAILURE CODE [CA3167] 1503
FAILURE CODE [CA3229] 1506
FAILURE CODE [CA3231] 1508
FAILURE CODE [CA3232] 1510
FAILURE CODE [CA3235] 1514
FAILURE CODE [CA3239] 1516
FAILURE CODE [CA3241] 1519
FAILURE CODE [CA3242] 1522
FAILURE CODE [CA3251] 1525
FAILURE CODE [CA3253] 1528
FAILURE CODE [CA3254] 1532
FAILURE CODE [CA3255] 1535
FAILURE CODE [CA3256] 1539
FAILURE CODE [CA3311] 1541
FAILURE CODE [CA3312] 1543
FAILURE CODE [CA3313] 1546
FAILURE CODE [CA3314] 1547
FAILURE CODE [CA3315] 1548
FAILURE CODE [CA3316] 1551
FAILURE CODE [CA3317] 1552
FAILURE CODE [CA3318] 1553
FAILURE CODE [CA3319] 1556
FAILURE CODE [CA3321] 1557
FAILURE CODE [CA3322] 1559
FAILURE CODE [CA3419] 1562
FAILURE CODE [CA3421] 1564
FAILURE CODE [CA3497] 1566
FAILURE CODE [CA3498] 1567
FAILURE CODE [CA3543] 1568
FAILURE CODE [CA3545] 1575
FAILURE CODE [CA3547] 1577
FAILURE CODE [CA3558] 1578
FAILURE CODE [CA3559] 1580
FAILURE CODE [CA3562] 1582
FAILURE CODE [CA3563] 1584
FAILURE CODE [CA3567] 1587
FAILURE CODE [CA3568] 1590
FAILURE CODE [CA3571] 1594
FAILURE CODE [CA3572] 1596
FAILURE CODE [CA3574] 1598
FAILURE CODE [CA3575] 1600
FAILURE CODE [CA3577] 1602
FAILURE CODE [CA3578] 1604
FAILURE CODE [CA3582] 1606
FAILURE CODE [CA3583] 1613
FAILURE CODE [CA3596] 1615
FAILURE CODE [CA3649] 1617
FAILURE CODE [CA3681] 1619
FAILURE CODE [CA3682] 1624
FAILURE CODE [CA3713] 1630
FAILURE CODE [CA3717] 1633
FAILURE CODE [CA3718] 1634
FAILURE CODE [CA3725] 1635
FAILURE CODE [CA3748] 1638
FAILURE CODE [CA3751] 1641
FAILURE CODE [CA3755] 1643
FAILURE CODE [CA3866] 1645
FAILURE CODE [CA3867] 1649
FAILURE CODE [CA3868] 1652
FAILURE CODE [CA3899] 1656
FAILURE CODE [CA3911] 1658
FAILURE CODE [CA3912] 1662
FAILURE CODE [CA3932] 1664
FAILURE CODE [CA3933] 1666
FAILURE CODE [CA3934] 1668
FAILURE CODE [CA3935] 1671
FAILURE CODE [CA3936] 1673
FAILURE CODE [CA4151] 1675
FAILURE CODE [CA4152] 1679
FAILURE CODE [CA4155] 1683
FAILURE CODE [CA4156] 1685
FAILURE CODE [CA4157] 1688
FAILURE CODE [CA4158] 1690
FAILURE CODE [CA4159] 1691
FAILURE CODE [CA4161] 1692
FAILURE CODE [CA4162] 1695
FAILURE CODE [CA4163] 1698
FAILURE CODE [CA4164] 1700
FAILURE CODE [CA4165] 1702
FAILURE CODE [CA4166] 1704
FAILURE CODE [CA4168] 1706
FAILURE CODE [CA4169] 1709
FAILURE CODE [CA4171] 1711
FAILURE CODE [CA4249] 1714
FAILURE CODE [CA4251] 1716
FAILURE CODE [CA4259] 1718
FAILURE CODE [CA4261] 1721
FAILURE CODE [CA4277] 1724
FAILURE CODE [CA4281] 1728
FAILURE CODE [CA4459] 1732
FAILURE CODE [CA4461] 1735
FAILURE CODE [CA4658] 1738
FAILURE CODE [CA4731] 1742
FAILURE CODE [CA4732] 1743
FAILURE CODE [CA4739] 1744
FAILURE CODE [CA4768] 1745
FAILURE CODE [CA4769] 1747
FAILURE CODE [CA4842] 1750
FAILURE CODE [CA4952] 1754
FAILURE CODE [CA5115] 1756
FAILURE CODE [CA5383] 1759
FAILURE CODE [D130KA] 1761
FAILURE CODE [D130KB] 1764
FAILURE CODE [D141KA] 1766
FAILURE CODE [D141KB] 1768
FAILURE CODE [D141KY] 1770
FAILURE CODE [D162KA] 1772
FAILURE CODE [D162KB] 1774
FAILURE CODE [D162KY] 1776
FAILURE CODE [D190KA] 1778
FAILURE CODE [D190KB] 1780
FAILURE CODE [D19CKA] 1782
FAILURE CODE [D19CKB] 1784
FAILURE CODE [D19CKY] 1786
FAILURE CODE [D19DKA] 1788
FAILURE CODE [D19DKB] 1790
FAILURE CODE [D19DKY] 1792
FAILURE CODE [D19EKA] 1794
FAILURE CODE [D19EKB] 1796
FAILURE CODE [D19EKY] 1798
FAILURE CODE [D19FKA] 1800
FAILURE CODE [D19FKB] 1802
FAILURE CODE [D19FKY] 1804
FAILURE CODE [D19GKA] 1806
FAILURE CODE [D19GKB] 1808
FAILURE CODE [D19GKY] 1810
FAILURE CODE [D19JKZ] 1812
FAILURE CODE [D811MC] 1815
FAILURE CODE [D862KA] 1816
FAILURE CODE [D8ALKA] 1817
FAILURE CODE [D8ALKB] 1819
FAILURE CODE [D8AQKR] 1822
FAILURE CODE [DAF0MB] 1823
FAILURE CODE [DAF0MC] 1824
FAILURE CODE [DAF8KB] 1825
FAILURE CODE [DAF9KQ] 1826
FAILURE CODE [DAFGMC] 1827
FAILURE CODE [DAFLKA] 1828
FAILURE CODE [DAFLKB] 1830
FAILURE CODE [DAFQKR] 1833
FAILURE CODE [DAZ9KQ] 1834
FAILURE CODE [DAZQKR] 1835
FAILURE CODE [DB2QKR] 1836
FAILURE CODE [DB2RKR] 1843
FAILURE CODE [DB90KT] 1849
FAILURE CODE [DB90MC] 1850
FAILURE CODE [DB91KK] 1851
FAILURE CODE [DB92KK] 1854
FAILURE CODE [DB95KK] 1856
FAILURE CODE [DB97KK] 1859
FAILURE CODE [DB99KQ] 1861
FAILURE CODE [DB9LKA] 1863
FAILURE CODE [DB9LKB] 1865
FAILURE CODE [DB9QKR] 1867
FAILURE CODE [DB9RKR] 1868
FAILURE CODE [DBE0KT] 1870
FAILURE CODE [DBE0MC] 1871
FAILURE CODE [DBE1KK] 1872
FAILURE CODE [DBE2KK] 1875
FAILURE CODE [DBE5KK] 1878
FAILURE CODE [DBE6KK] 1880
FAILURE CODE [DBE9KQ] 1882
FAILURE CODE [DBELKA] 1883
FAILURE CODE [DBELKB] 1885
FAILURE CODE [DBEQKR] 1887
FAILURE CODE [DBERKR] 1888
FAILURE CODE [DBTSKR] 1890
FAILURE CODE [DBUTKA] 1893
FAILURE CODE [DD12KA] 1894
FAILURE CODE [DD12KB] 1896
FAILURE CODE [DD13KA] 1898
FAILURE CODE [DD13KB] 1900
FAILURE CODE [DD14KA] 1902
FAILURE CODE [DD14KB] 1905
FAILURE CODE [DDDDKA] 1907
FAILURE CODE [DDDDKB] 1910
FAILURE CODE [DDDDKX] 1913
FAILURE CODE [DDKAKA] 1914
FAILURE CODE [DDKAKB] 1916
FAILURE CODE [DDKBKA] 1918
FAILURE CODE [DDKBKB] 1920
FAILURE CODE [DDKCL4] 1922
FAILURE CODE [DDKEL4] 1925
FAILURE CODE [DDKQKA] 1928
FAILURE CODE [DDKQKB] 1930
FAILURE CODE [DDKRKA] 1932
FAILURE CODE [DDKRKB] 1934
FAILURE CODE [DDKSKA] 1936
FAILURE CODE [DDKSKB] 1938
FAILURE CODE [DDN7L4] 1941
FAILURE CODE [DDN8L4] 1944
FAILURE CODE [DDNLKA] 1947
FAILURE CODE [DDNLKB] 1949
FAILURE CODE [DDTSL1] 1951
FAILURE CODE [DDTSLH] 1953
FAILURE CODE [DFA4KX] 1955
FAILURE CODE [DFA4KZ] 1956
FAILURE CODE [DFA4L8] 1957
FAILURE CODE [DFA5KA] 1958
FAILURE CODE [DFA5KY] 1961
FAILURE CODE [DFA6KA] 1963
FAILURE CODE [DFA6KY] 1966
FAILURE CODE [DFA7KX] 1968
FAILURE CODE [DFA7KZ] 1969
FAILURE CODE [DFA7L8] 1970
FAILURE CODE [DFA8KA] 1971
FAILURE CODE [DFA8KY] 1974
FAILURE CODE [DFA9KA] 1976
FAILURE CODE [DFA9KY] 1979
FAILURE CODE [DFAAKX] 1981
FAILURE CODE [DFAAKZ] 1982
FAILURE CODE [DFAAL8] 1983
FAILURE CODE [DFABKA] 1984
FAILURE CODE [DFABKY] 1987
FAILURE CODE [DFACKA] 1989
FAILURE CODE [DFACKY] 1992
FAILURE CODE [DGS1KA] 1994
FAILURE CODE [DGS1KX] 1996
FAILURE CODE [DGT1KA] 1998
FAILURE CODE [DGT1KX] 2001
FAILURE CODE [DH21KA] 2003
FAILURE CODE [DH21KY] 2006
FAILURE CODE [DHA4KA] 2008
FAILURE CODE [DHAAMA] 2010
FAILURE CODE [DHACMA] 2012
FAILURE CODE [DHT5KA] 2014
FAILURE CODE [DHT5KY] 2017
FAILURE CODE [DHT7KA] 2019
FAILURE CODE [DHT7KY] 2022
FAILURE CODE [DK10KA] 2024
FAILURE CODE [DK10KB] 2027
FAILURE CODE [DK30KA] 2029
FAILURE CODE [DK30KX] 2032
FAILURE CODE [DK30KY] 2033
FAILURE CODE [DK30KZ] 2035
FAILURE CODE [DK30L8] 2036
FAILURE CODE [DK31KA] 2037
FAILURE CODE [DK31KY] 2040
FAILURE CODE [DK40KA] 2042
FAILURE CODE [DK40KY] 2045
FAILURE CODE [DK55KX] 2047
FAILURE CODE [DK55KZ] 2048
FAILURE CODE [DK55L8] 2049
FAILURE CODE [DK56KA] 2050
FAILURE CODE [DK56KY] 2053
FAILURE CODE [DK57KA] 2055
FAILURE CODE [DK57KY] 2058
FAILURE CODE [DK80KA] 2060
FAILURE CODE [DKH1KA] 2063
FAILURE CODE [DKH1KY] 2066
FAILURE CODE [DKSGL8] 2068
FAILURE CODE [DKSHKA] 2070
FAILURE CODE [DKSHKB] 2072
FAILURE CODE [DKSJKA] 2074
FAILURE CODE [DKSJKB] 2076
FAILURE CODE [DKSKKA] 2078
FAILURE CODE [DKSKKB] 2080
FAILURE CODE [DKSKMB] 2082
FAILURE CODE [DKSLL8] 2084
FAILURE CODE [DKSMKA] 2086
FAILURE CODE [DKSMKB] 2088
FAILURE CODE [DKSNKA] 2090
FAILURE CODE [DKSNKB] 2092
FAILURE CODE [DKSPKA] 2094
FAILURE CODE [DKSPKB] 2096
FAILURE CODE [DKSPMB] 2098
FAILURE CODE [DLM3KA] 2100
FAILURE CODE [DLM3KB] 2102
FAILURE CODE [DLM3MB] 2103
FAILURE CODE [DLT3KA] 2104
FAILURE CODE [DLT3KB] 2106
FAILURE CODE [DR21KX] 2108
FAILURE CODE [DR31KX] 2109
FAILURE CODE [DV20KB] 2110
FAILURE CODE [DW7BKA] 2112
FAILURE CODE [DW7BKB] 2114
FAILURE CODE [DWN1KA] 2116
FAILURE CODE [DWN1KB] 2118
FAILURE CODE [DWN1KY] 2120
FAILURE CODE [DWN2KA] 2121
FAILURE CODE [DWN2KB] 2123
FAILURE CODE [DWN2KY] 2124
FAILURE CODE [DWN3KA] 2125
FAILURE CODE [DWN3KB] 2127
FAILURE CODE [DWN3KY] 2129
FAILURE CODE [DWN5KA] 2131
FAILURE CODE [DWN5KB] 2133
FAILURE CODE [DWN5KY] 2135
FAILURE CODE [DXA2KA] 2137
FAILURE CODE [DXA2KB] 2139
FAILURE CODE [DXA2KY] 2141
FAILURE CODE [DXH1KA] 2143
FAILURE CODE [DXH1KB] 2145
FAILURE CODE [DXH1KY] 2147
FAILURE CODE [DXH4KA] 2149
FAILURE CODE [DXH4KB] 2151
FAILURE CODE [DXH4KY] 2153
FAILURE CODE [DXH5KA] 2155
FAILURE CODE [DXH5KB] 2156
FAILURE CODE [DXH5KY] 2157
FAILURE CODE [DXH6KA] 2158
FAILURE CODE [DXH6KB] 2160
FAILURE CODE [DXH6KY] 2161
FAILURE CODE [DXH7KA] 2163
FAILURE CODE [DXH7KB] 2165
FAILURE CODE [DXH7KY] 2167
FAILURE CODE [DXH8KA] 2169
FAILURE CODE [DXH8KB] 2171
FAILURE CODE [DXH8KY] 2173
FAILURE CODE [DXHBKA] 2175
FAILURE CODE [DXHBKB] 2177
FAILURE CODE [DXHBKY] 2179
FAILURE CODE [DXHCKA] 2181
FAILURE CODE [DXHCKB] 2183
FAILURE CODE [DXHCKY] 2185
FAILURE CODE [DXHRKA] 2187
FAILURE CODE [DXHRKB] 2189
FAILURE CODE [DXHRKY] 2190
FAILURE CODE [DXHSKA] 2192
FAILURE CODE [DXHSKB] 2194
FAILURE CODE [DXHSKY] 2195
FAILURE CODE [DXHTKA] 2197
FAILURE CODE [DXHTKB] 2199
FAILURE CODE [DXHTKY] 2201
FAILURE CODE [DXHUKA] 2203
FAILURE CODE [DXHUKB] 2205
FAILURE CODE [DXHUKY] 2207
FAILURE CODE [DXHWKA] 2209
FAILURE CODE [DXHWKB] 2211
FAILURE CODE [DXHWKY] 2212
FAILURE CODE [DXHXKA] 2214
FAILURE CODE [DXHXKB] 2216
FAILURE CODE [DXHXKY] 2217
FAILURE CODE [DXHYKA] 2219
FAILURE CODE [DXHYKB] 2221
FAILURE CODE [DXHYKY] 2222
FAILURE CODE [DXHZKA] 2224
FAILURE CODE [DXHZKB] 2226
FAILURE CODE [DXHZKY] 2227
FAILURE CODE [DXJ4KA] 2229
FAILURE CODE [DXJ4KB] 2231
FAILURE CODE [DXJ8KA] 2232
FAILURE CODE [DXJ8KB] 2234
FAILURE CODE [DXJ8KY] 2236
FAILURE CODE [DXJ9KA] 2238
FAILURE CODE [DXJ9KB] 2240
FAILURE CODE [DXJ9KY] 2242
FAILURE CODE [DXJAKA] 2244
FAILURE CODE [DXJAKB] 2246
FAILURE CODE [DXJAKY] 2248
FAILURE CODE [DXJBKA] 2250
FAILURE CODE [DXJBKB] 2252
FAILURE CODE [DXJBKY] 2254
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2256
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2256
E-2 ENGINE DOES NOT START IN RADIO CONTROL MODE (ENGINE DOES NOT CRANK) 2263
E-3 ENGINE STOPS DURING OPERATION (SPECIFICATIONS OF RADIO CONTROL) 2266
E-4 MANUAL PREHEATING SYSTEM DOES NOT WORK 2270
E-5 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2273
E-6 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2275
E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2277
E-8 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2281
E-9 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2283
E-10 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2284
E-11 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2286
E-12 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2287
E-13 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2288
E-14 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2289
E-15 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2290
E-16 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2291
E-17 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2293
E-18 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 2294
E-19 OPERATION MODE DOES NOT CHANGE 2295
E-20 GEAR SHIFT MODE DOES NOT CHANGE 2296
E-21 MOVEMENT OF MACHINE DOES NOT MATCH TO INSTRUCTIONS IN RADIO CONTROL TRANSMITTER OPERATION 2297
E-22 RADIO CONTROL/ON-BOARD CAN NOT BE CHANGED 2300
E-23 ALL RADIO CONTROL CAN NOT BE OPERATED 2302
E-24 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 2304
E-25 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 2305
E-26 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2306
E-27 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING 2307
E-28 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2308
E-29 SERVICE MODE CANNOT BE SELECTED 2309
E-30 HORN DOES NOT SOUND 2310
E-31 HORN DOES NOT STOP SOUNDING 2312
E-32 HORN DOES NOT SOUND OR DOES NOT STOP SOUNDING (SPECIFICATIONS OF RADIO CONTROL) 2313
E-33 BACKUP ALARM DOES NOT SOUND 2315
E-34 BACKUP ALARM DOES NOT STOP SOUNDING 2316
E-35 HEADLAMP DOES NOT LIGHT UP 2317
E-36 REAR LAMP AND RIPPER POINT LAMP DO NOT LIGHT UP 2321
E-37 WORKING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2325
E-38 RED REVOLVING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2329
E-39 YELLOW REVOLVING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2332
E-40 BLUE REVOLVING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2335
E-41 GREEN REVOLVING LAMP DOES NOT LIGHT UP OR GO OUT (SPECIFICATIONS OF RADIO CONTROL) 2338
E-42 ALL WIPERS DO NOT OPERATE 2341
E-43 FRONT WIPER DOES NOT OPERATE 2346
E-44 REAR WIPER DOES NOT OPERATE 2350
E-45 LEFT DOOR WIPER DOES NOT OPERATE 2354
E-46 RIGHT DOOR WIPER DOES NOT OPERATE 2358
E-1 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY 2362
E-48 FAN DOES NOT ROTATE IN REVERSE 2363
E-49 GEAR CANNOT BE SHIFTED 2364
E-50 FRONT WASHER DOES NOT OPERATE 2365
E-51 REAR WASHER DOES NOT OPERATE 2368
E-52 LEFT DOOR WASHER DOES NOT OPERATE 2371
E-53 RIGHT DOOR WASHER DOES NOT OPERATE 2374
E-54 RIPPER PIN PULLER DOES NOT WORK 2377
E-55 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2379
E-56 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !] 2380
E-57 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !] 2384
E-58 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link ] 2387
E-59 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected] 2388
E-60 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites ] 2389
E-61 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] 2390
E-62 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal] 2392
E-63 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal] 2393
E-64 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble] 2394
E-65 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize ] 2395
E-66 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing] 2396
E-67 CONTROL BOX DISPLAYS THE MESSAGE [Initializing ] 2397
E-68 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS] 2398
E-69 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization ] 2399
E-70 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions ] 2400
E-71 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing] 2401
E-72 CONTROL BOX DISPLAYS [Out of design area ] 2402
E-73 CONTROL BOX CAN NOT BE TURNED ON 2403
E-74 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN 2404
E-75 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE 2405
E-76 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE 2406
E-77 CONTROL BOX TOUCH PANEL DOES NOT RESPOND 2407
E-78 CONTROL BOX TOUCH PANEL IS INACCURATE 2408
E-79 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT 2409
E-80 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT) 2410
E-81 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2411
E-82 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 2412
E-83 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS) 2413
E-84 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE 2414
E-85 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) 2415
E-86 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH) 2416
E-87 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION) 2417
E-88 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS) 2418
E-89 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE 2419
E-90 WHEN PRESSING CUT/FILL LEVEL SWITCH (RAISE), THE DESIGN SURFACE DOES NOT RISE 2421
E-91 WHEN PRESSING CUT/FILL LEVEL SWITCH (LOWER), THE DESIGN SURFACE DOES NOT LOWER 2424
E-92 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT 2427
E-93 WHEN REVERSE LEVELING MODE SWITCH IS PRESSED, BUZZER DOES NOT SOUND (DOES NOT SWITCH TO REVERSE LEVELING MODE) 2429
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2432
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2432
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2433
FAILURE MODE AND CAUSE TABLE 2437
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) 2445
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) 2448
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 2450
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE 2453
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE 2455
H-6 BRAKE DOES NOT WORK 2457
H-7 POWER TRAIN OIL OVERHEATS 2458
H-8 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND HSS PUMP OR HSS MOTOR 2460
H-9 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 2461
H-10 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT) 2462
H-11 STEERING SPEED OR POWER IS INSUFFICIENT 2464
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY 2466
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE 2468
H-14 BLADE LIFT SPEED OR POWER IS LOW 2470
H-15 BLADE TILT SPEED OR POWER IS LOW 2472
H-16 RIPPER LIFT SPEED OR POWER IS LOW 2474
H-17 RIPPER TILT SPEED OR POWER IS LOW 2476
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 2478
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 2479
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE 2480
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 2481
H-22 BLADE PITCH CYLINDER DOES NOT OPERATE 2482
H-23 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2483
H-24 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2484
TROUBLESHOOTING OF ENGINE (S-MODE) 2485
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2485
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2486
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2487
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2488
S-4 ENGINE STARTABILITY IS POOR 2489
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2491
S-6 ENGINE STOPS DURING OPERATION 2493
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2495
S-8 ENGINE LACKS POWER 2496
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2498
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2500
S-11 OIL BECOMES CONTAMINATED QUICKLY 2501
S-1 FUEL CONSUMPTION IS EXCESSIVE 2502
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2503
S-14 OIL PRESSURE DROPS 2504
S-15 FUEL MIXES INTO ENGINE OIL 2506
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2507
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2508
S-18 UNUSUAL NOISE IS HEARD 2509
S-19 VIBRATION IS EXCESSIVE 2510
S-2 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2511
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2512
S-22 ACTIVE REGENERATION TAKES TIME 2514
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2516
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2517
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2519
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2520
50 DISASSEMBLY AND ASSEMBLY 2521
CONTENTS 2522
ABBREVIATION LIST 2528
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2534
HOW TO READ THIS MANUAL 2534
COATING MATERIALS LIST 2536
SPECIAL TOOLS LIST 2540
SKETCHES OF SPECIAL TOOLS 2567
ENGINE AND COOLING SYSTEM 2594
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2594
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2594
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2596
REMOVE AND INSTALL INJECTOR ASSEMBLY 2602
METHOD FOR REMOVING INJECTOR ASSEMBLY 2602
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2608
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2617
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2617
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2618
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2619
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2620
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2630
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2646
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2646
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2647
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2649
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2649
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2651
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2654
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2654
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2655
REMOVE AND INSTALL ALTERNATOR BELT 2657
METHOD FOR REMOVING ALTERNATOR BELT 2657
METHOD FOR INSTALLING ALTERNATOR BELT 2658
REMOVE AND INSTALL RADIATOR ASSEMBLY 2660
METHOD FOR REMOVING RADIATOR ASSEMBLY 2660
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2663
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2669
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2669
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2670
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2672
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2672
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2673
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2676
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2676
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2678
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2680
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2680
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2681
REMOVE AND INSTALL ENGINE ASSEMBLY 2683
METHOD FOR REMOVING ENGINE ASSEMBLY 2683
METHOD FOR INSTALLING ENGINE ASSEMBLY 2690
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2697
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2697
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2699
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2703
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2703
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2705
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2709
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2709
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2712
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2715
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2715
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2718
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2722
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2722
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2728
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2733
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2733
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2739
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2744
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2744
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2744
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2751
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2751
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2751
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2752
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2752
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2753
REMOVE AND INSTALL KDPF ASSEMBLY 2756
METHOD FOR REMOVING KDPF ASSEMBLY 2756
METHOD FOR INSTALLING KDPF ASSEMBLY 2760
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2764
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2764
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2769
REMOVE AND INSTALL SCR ASSEMBLY 2774
METHOD FOR REMOVING SCR ASSEMBLY 2774
METHOD FOR INSTALLING SCR ASSEMBLY 2777
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2782
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2782
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2787
REMOVE AND INSTALL KCCV ASSEMBLY 2794
METHOD FOR REMOVING KCCV ASSEMBLY 2794
METHOD FOR INSTALLING KCCV ASSEMBLY 2796
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2799
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2799
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2802
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2807
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2807
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2810
REMOVE AND INSTALL AdBlue/DEF PUMP 2813
METHOD FOR REMOVING AdBlue/DEF PUMP 2813
METHOD FOR INSTALLING AdBlue/DEF PUMP 2817
REMOVE AND INSTALL AdBlue/DEF HOSE 2821
METHOD FOR REMOVING AdBlue/DEF HOSE 2821
METHOD FOR INSTALLING AdBlue/DEF HOSE 2827
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2833
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2833
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2834
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2836
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2836
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2837
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2838
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2838
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2839
POWER TRAIN 2842
REMOVE AND INSTALL DAMPER ASSEMBLY 2842
METHOD FOR REMOVING DAMPER ASSEMBLY 2842
METHOD FOR INSTALLING DAMPER ASSEMBLY 2844
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY 2847
METHOD FOR DISASSEMBLE DAMPER ASSEMBLY 2848
METHOD FOR ASSEMBLING DAMPER ASSEMBLY 2849
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY 2852
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY 2852
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY 2857
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY 2862
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY 2862
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY 2868
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY 2874
METHOD FOR DISASSEMBLING PTO ASSEMBLY 2874
METHOD FOR ASSEMBLING PTO ASSEMBLY 2878
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2885
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2885
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2891
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2899
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2900
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2910
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY 2923
METHOD FOR DISASSEMBLING HSS ASSEMBLY 2925
METHOD FOR ASSEMBLING HSS ASSEMBLY 2934
REMOVAL AND INSTALLATION OF HSS MOTOR 2948
METHOD FOR REMOVING HSS MOTOR ASSEMBLY 2948
METHOD FOR INSTALLING HSS MOTOR ASSEMBLY 2949
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY 2951
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2951
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY 2953
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2956
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2958
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2965
UNDERCARRIAGE AND FRAME 2976
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2976
METHOD FOR REMOVING TRACK FRAME ASSEMBLY 2976
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY 2981
REMOVE AND INSTALL IDLER ASSEMBLY 2986
METHOD FOR REMOVING IDLER ASSEMBLY 2986
METHOD FOR INSTALLING IDLER ASSEMBLY 2987
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2989
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2989
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2990
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2994
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2994
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2994
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2995
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2995
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2999
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 3002
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 3002
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 3004
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 3006
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 3006
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 3007
REMOVE AND INSTALL NO 1 BOGIE ASSEMBLY 3010
METHOD FOR REMOVING NO 1 BOGIE ASSEMBLY 3011
METHOD FOR INSTALLING NO 1 BOGIE ASSEMBLY 3014
REMOVE AND INSTALL NO 2, 3, 4 BOGIE ASSEMBLIES 3019
METHOD FOR REMOVING NO 2, 3, 4 BOGIE ASSEMBLIES 3020
METHOD FOR INSTALLING NO 2, 3, 4 BOGIE ASSEMBLIES 3022
DISASSEMBLE AND ASSEMBLE TRACK ROLLER BOGEY ASSEMBLY 3027
METHOD FOR DIS ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY 3027
METHOD FOR ASSEMBLING TRACK ROLLER BOGEY ASSEMBLY 3028
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 3030
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 3030
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 3031
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 3032
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 3032
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 3034
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 3037
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 3037
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 3038
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 3039
METHOD FOR CHECKING BEFORE SEPARATION OF THE TRACK ASSEMBLY 3039
METHOD FOR SEPARATING OF TRACK ASSEMBLY (NORMAL) 3039
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 3040
METHOD FOR INSTALLING TRACK ASSEMBLY 3042
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 3044
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 3044
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 3044
DISASSEMBLY AND ASSEMBLY OF TRACK ASSEMBLY GENERALLY 3045
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 3045
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 3047
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 3060
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 3060
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 3061
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD 3070
METHOD FOR DISASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 3071
METHOD FOR ASSEMBLING ONE TRACK LINK ASSEMBLY IN FIELD 3073
DISASSEMBLE AND ASSEMBLE MASTER LINK 3075
METHOD FOR DISASSEMBLING MASTER LINK 3075
METHOD FOR ASSEMBLING MASTER LINK 3076
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 3079
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 3079
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 3081
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS 3083
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS 3083
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS 3084
REMOVE AND INSTALL SPROCKET 3085
METHOD FOR REMOVING SPROCKET 3085
METHOD FOR INSTALLING SPROCKET 3085
REMOVE AND INSTALL UNDER GUARD ASSEMBLY 3086
METHOD FOR REMOVING UNDER GUARD ASSEMBLY 3086
METHOD FOR INSTALLING UNDER GUARD ASSEMBLY 3093
HYDRAULIC SYSTEM 3101
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3101
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3101
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3102
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 3104
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 3104
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND HSS PUMP ASSEMBLY 3106
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 3108
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 3108
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 3110
REMOVE AND INSTALL COOLING FAN PUMP ASSEMBLY 3112
METHOD FOR REMOVING COOLING FAN PUMP ASSEMBLY 3112
METHOD FOR INSTALLING COOLING FAN PUMP ASSEMBLY 3114
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY 3116
METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY 3116
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY 3117
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3118
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 3118
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 3119
WORK EQUIPMENT 3122
REMOVE AND INSTALL BLADE ASSEMBLY 3122
METHOD FOR REMOVING BLADE ASSEMBLY 3122
METHOD FOR INSTALLING BLADE ASSEMBLY 3124
DISASSEMBLE AND ASSEMBLE BLADE ASSEMBLY 3127
METHOD FOR DISASSEMBLING BLADE ASSEMBLY 3127
METHOD FOR ASSEMBLING BLADE ASSEMBLY 3130
DISASSEMBLE AND ASSEMBLE FIXED MULTI-SHANK RIPPER ASSEMBLY 3133
METHOD FOR DISASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY 3133
METHOD FOR ASSEMBLING FIXED MULTI-SHANK RIPPER ASSEMBLY 3135
DISASSEMBLE AND ASSEMBLE GIANT RIPPER ASSEMBLY 3138
METHOD FOR DISASSEMBLING GIANT RIPPER ASSEMBLY 3138
METHOD FOR ASSEMBLING GIANT RIPPER ASSEMBLY 3141
REMOVE AND INSTALL STROKE AND RESET SENSING BLADE LIFT CYLINDER ASSEMBLY 3144
REMOVE STROKE AND RESET SENSING BLADE LIFT CYLINDER ASSEMBLY 3146
INSTALL STROKE AND RESET SENSING BLADE LIFT CYLINDER ASSEMBLY 3150
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3154
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3155
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY 3160
METHOD FOR DISASSEMBLING AND ASSEMBLING BLADE TILT CYLINDER ASSEMBLY 3172
METHOD FOR DISASSEMBLING BLADE TILT CYLINDER ASSEMBLY 3172
METHOD FOR ASSEMBLING BLADE TILT CYLINDER ASSEMBLY 3174
METHOD FOR DISASSEMBLING AND ASSEMBLING RIPPER CYLINDER ASSEMBLY 3177
METHOD FOR DISASSEMBLING RIPPER CYLINDER ASSEMBLY 3177
METHOD FOR ASSEMBLING RIPPER CYLINDER ASSEMBLY 3179
CAB AND ITS ATTACHMENTS 3184
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3184
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3185
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3195
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3204
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 3206
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 3206
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3211
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3211
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3217
REMOVE AND INSTALL OPERATOR’S SEAT 3224
METHOD FOR REMOVING OPERATOR’S SEAT 3224
METHOD FOR INSTALLING OPERATOR’S SEAT 3225
REMOVE AND INSTALL SEAT BELT 3226
METHOD FOR REMOVING SEAT BELT 3226
METHOD FOR INSTALLING SEAT BELT 3227
ELECTRICAL SYSTEM 3228
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3228
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3228
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3231
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY 3234
METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY 3234
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY 3235
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3236
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3236
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3236
REMOVE AND INSTALL RADIO CONTROL CONTROLLER 3238
METHOD FOR REMOVING RADIO CONTROL CONTROLLER 3238
METHOD FOR INSTALLING RADIO CONTROL CONTROLLER 3238
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3240
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3240
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3241
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3243
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3243
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3244
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3246
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3246
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3247
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3248
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3248
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3250
REMOVE AND INSTALL BATTERY RELAY 3252
METHOD FOR REMOVING BATTERY RELAY 3252
METHOD FOR INSTALLING BATTERY RELAY 3260
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3265
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3265
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3267
REMOVE AND INSTALL CONTROL BOX 3270
METHOD FOR REMOVING CONTROL BOX (FOR OLD CONTROL BOX) 3270
METHOD FOR REMOVING CONTROL BOX (FOR NEW CONTROL BOX) 3271
METHOD FOR INSTALLING CONTROL BOX (FOR OLD CONTROL BOX) 3271
METHOD FOR INSTALLING CONTROL BOX (FOR NEW CONTROL BOX) 3272
REMOVE AND INSTALL GNSS RECEIVER 3274
METHOD FOR REMOVING GNSS RECEIVER 3274
METHOD FOR INSTALLING GNSS RECEIVER 3275
REMOVE AND INSTALL GNSS ANTENNA 3276
METHOD FOR REMOVING GNSS ANTENNA 3276
METHOD FOR INSTALLING GNSS ANTENNA 3277
REMOVE AND INSTALL IMU SENSOR 3282
METHOD FOR REMOVING IMU SENSOR 3282
METHOD FOR INSTALLING IMU SENSOR 3284
REMOVE AND INSTALL RADIO CONTROL RECEIVER 3288
METHOD FOR REMOVING RADIO CONTROL RECEIVER 3288
METHOD FOR INSTALLING RADIO CONTROL RECEIVER 3288
REMOVE AND INSTAL REVOLVING LAMP 3290
METHOD FOR REMOVING REVOLVING LAMP 3290
METHOD FOR INSTALLING REVOLVING LAMP 3291
REMOVE AND INSTAL RADIO CONTROL ANTENNA 3292
METHOD FOR REMOVING RADIO CONTROL ANTENNA 3292
METHOD FOR INSTALLING RADIO CONTROL ANTENNA 3292
60 MAINTENANCE STANDARD 3293
CONTENTS 3294
ABBREVIATION LIST 3296
ENGINE AND COOLING SYSTEM 3302
MAINTENANCE STANDARD OF ENGINE MOUNT 3302
MAINTENANCE STANDARD OF DAMPER 3304
MAINTENANCE STANDARD OF COOLING SYSTEM 3306
MAINTENANCE STANDARD OF COOLING FAN PUMP 3308
MAINTENANCE STANDARD OF SERVO VALVE 3310
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3312
POWER TRAIN 3314
MAINTENANCE STANDARD OF UNIVERSAL JOINT 3314
MAINTENANCE STANDARD OF POWER TRAIN MOUNT 3315
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 3317
MAINTENANCE STANDARD OF TORQUE CONVERTER CONTROL VALVE 3322
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3323
MAINTENANCE STANDARD OF STATOR CLUTCH ECMV 3324
MAINTENANCE STANDARD OF TRANSMISSION 3325
MAINTENANCE STANDARD OF TRANSMISSION ECMV 3330
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3331
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE 3332
MAINTENANCE STANDARD OF BEVEL GEAR SHAFT, HSS, AND BRAKE 3333
MAINTENANCE STANDARD OF BRAKE CONTROL VALVE 3339
MAINTENANCE STANDARD OF BRAKE ECMV 3341
MAINTENANCE STANDARD OF BRAKE SOLENOID VALVE 3342
MAINTENANCE STANDARD OF SUDDEN STOP PREVENTION VALVE 3343
MAINTENANCE STANDARD OF FINAL DRIVE 3344
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 3347
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 3348
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 3350
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 3351
UNDERCARRIAGE AND FRAME 3353
MAINTENANCE STANDARD OF MAIN FRAME 3353
MAINTENANCE STANDARD OF SUSPENSION 3355
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 3357
MAINTENANCE STANDARD OF IDLER 3359
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES 3361
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES 3363
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE 3365
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 3366
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 3367
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 3369
MAINTENANCE STANDARD OF SINGLE SHOE AND HEAVY DUTY SHOE 3371
HYDRAULIC SYSTEM 3372
MAINTENANCE STANDARD OF HYDRAULIC TANK 3372
MAINTENANCE STANDARD OF SCAVENGING PUMP 3373
MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 3374
MAINTENANCE STANDARD OF WORK EQUIPMENT AND HSS PUMP 3376
MAINTENANCE STANDARD OF PC-EPC VALVE 3378
MAINTENANCE STANDARD OF HSS MOTOR 3379
MAINTENANCE STANDARD OF CONTROL VALVE 3382
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE 3396
MAINTENANCE STANDARD OF QUICK DROP VALVE 3398
WORK EQUIPMENT 3400
MAINTENANCE STANDARD OF CYLINDER STAY 3400
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 3402
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 3404
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER 3405
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 3406
MAINTENANCE STANDARD OF VARIABLE MULTI-SHANK RIPPER 3407
MAINTENANCE STANDARD OF VARIABLE GIANT RIPPER 3410
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 3413
MAINTENANCE STANDARD OF RIPPER TILT CYLINDER 3414
CAB AND ITS ATTACHMENTS 3415
MAINTENANCE STANDARD OF CAB MOUNT 3415
80 APPENDIX 3417
CONTENTS 3418
ABBREVIATION LIST 3420
AIR CONDITIONER SYSTEM 3426
PRECAUTIONS FOR REFRIGERANT 3426
AIR CONDITIONER COMPONENT 3427
SPECIFICATIONS OF AIR CONDITIONER 3429
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3430
OUTLINE OF REFRIGERATION CYCLE 3431
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3433
AIR CONDITIONER UNIT 3433
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3433
FUNCTION OF AIR CONDITIONER UNIT 3435
COMPONENT PARTS OF AIR CONDITIONER UNIT 3437
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3438
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3438
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3438
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3438
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3439
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3439
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3439
FUNCTION OF TRIPLE PRESSURE SWITCH 3440
AIR CONDITIONER CONTROLLER 3441
STRUCTURE OF AIR CONDITIONER CONTROLLER 3441
COMPRESSOR 3442
STRUCTURE OF COMPRESSOR 3442
SPECIFICATIONS OF COMPRESSOR 3442
FUNCTION OF COMPRESSOR 3442
CONDENSER 3443
STRUCTURE OF CONDENSER 3443
SPECIFICATIONS OF CONDENSER 3443
FUNCTION OF CONDENSER 3443
RECEIVER DRIER 3444
STRUCTURE OF RECEIVER DRIER 3444
SPECIFICATIONS OF RECEIVER DRIER 3444
FUNCTION OF RECEIVER DRIER 3444
SENSORS FOR AIR CONDITIONER SYSTEM 3445
STRUCTURE OF SUNLIGHT SENSOR 3445
FUNCTION OF SUNLIGHT SENSOR 3445
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3445
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3445
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3447
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3449
AIR CONDITIONER SYSTEM DIAGRAM 3451
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3452
FUNCTION OF AIR CONDITIONER CONTROLLER 3453
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3454
TESTING AIR LEAKAGE (DUCT) 3462
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3462
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3465
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3466
TEST VENT (MODE) CHANGEOVER 3467
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3467
TESTING FRESH/RECIRC AIR CHANGEOVER 3468
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3468
TEST SUNLIGHT SENSOR 3469
METHOD FOR TESTING SUNLIGHT SENSOR 3469
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 3470
METHOD FOR TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 3470
TEST RELAYS 3471
METHOD FOR TESTING RELAYS 3471
AIR CONDITIONER TROUBLESHOOTING CHART 1 3472
AIR CONDITIONER TROUBLESHOOTING CHART 2 3473
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3476
FAILURE CODE [879AKA] 3478
FAILURE CODE [879AKB] 3479
FAILURE CODE [879BKA] 3480
FAILURE CODE [879BKB] 3482
FAILURE CODE [879CKA] 3484
FAILURE CODE [879CKB] 3485
FAILURE CODE [879DKZ] 3486
FAILURE CODE [879EMC] 3488
FAILURE CODE [879FMC] 3489
FAILURE CODE [879GKX] 3490
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3492
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3493
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3494
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3495
TROUBLESHOOTING USING GAUGE PRESSURE 3496
CONNECTION OF SERVICE TOOL 3499
METHOD FOR CONNECTING SERVICE TOOL 3499
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3501
HANDLE COMPRESSOR OIL 3503
90 CIRCUIT DIAGRAMS 3505
CONTENTS 3506
ABBREVIATION LIST 3507
HYDRAULIC CIRCUIT DIAGRAM 3513
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3513
HYDRAULIC CIRCUIT DIAGRAM (1/2) 3517
HYDRAULIC CIRCUIT DIAGRAM (2/2) 3519
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3521
ELECTRICAL CIRCUIT DIAGRAM 3523
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3523
ELECTRICAL CIRCUIT DIAGRAM (1/17) 3527
ELECTRICAL CIRCUIT DIAGRAM (2/17) 3529
ELECTRICAL CIRCUIT DIAGRAM (3/17) 3531
ELECTRICAL CIRCUIT DIAGRAM (4/17) 3533
ELECTRICAL CIRCUIT DIAGRAM (5/17) 3535
ELECTRICAL CIRCUIT DIAGRAM (6/17) 3537
ELECTRICAL CIRCUIT DIAGRAM (7/17) 3539
ELECTRICAL CIRCUIT DIAGRAM (8/17) 3541
ELECTRICAL CIRCUIT DIAGRAM (9/17) 3543
ELECTRICAL CIRCUIT DIAGRAM (10/17) 3545
ELECTRICAL CIRCUIT DIAGRAM (11/17) 3547
ELECTRICAL CIRCUIT DIAGRAM (12/17) 3549
ELECTRICAL CIRCUIT DIAGRAM (13/17) 3551
ELECTRICAL CIRCUIT DIAGRAM (14/17) 3553
ELECTRICAL CIRCUIT DIAGRAM (15/17) 3555
ELECTRICAL CIRCUIT DIAGRAM (16/17) 3557
ELECTRICAL CIRCUIT DIAGRAM (17/17) 3559
INDEX 3561

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