Service manual Komatsu D375A-8R, D375Ai-8R 90001 & Up | SEN06984-02

Komatsu D375A-8R, D375Ai-8R 90001 & Up SEN06984-02 (Preview)

00 Index and Foreword
Index
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
How to Disconnect and Connect Type 1 Push-Pull Type Coupler
How to Disconnect and Connect Type 2 Push-Pull Type Coupler
How to Disconnect and Connect Type 3 Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
Standard Tightening Torque Table
Conversion Table
Abbreviation List
01 Specifications
Table of Contents
Specifications
Specification Drawing
Specification Drawing: D375A-8R
Specification Drawing: D375AI-8R
Specifications
Specifications: D375A-8R
Specifications: D375AI-8R
Weight Table
Weight Table: D375A-8R
Weight Table: D375AI-8R
Fuel, Coolant, Lubricant
How to Use Fuel, Coolant and Lubricants by Ambient Temperature
10 Structure and Function
Table of Contents
Boot-up System
System Operating Lamp System
System Diagram of System Operating Lamp System
Function of Operation Lamp System
Battery Disconnect Switch
Layout Drawing of Battery Disconnect Switch
Function of Battery Disconnect Switch
Battery Isolator
Layout Drawing of Battery Isolator
Function of Battery Isolator
Engine System
Layout Drawing of Engine System
Engine Control System
Layout Drawing of Engine Control System
System Diagram of Engine Control
Function of Engine Control System
Automatic Idle Stop System
System Diagram of Automatic Idle Stop System
Function of Automatic Idle Stop System
Operation of Automatic Idle Stop System
Component Parts of Engine System
Damper
Turbocharger
Muffler
Fuel System
Fuel System Circuit Diagram
Function of Fuel System
Operation of Fuel System
CRI System
Cooling System
Layout Drawing of Cooling System
Specifications of Cooling System
Component Parts of Cooling System
Cooling Fan Pump
Cooling Fan Motor
Hydraulic Oil Cooler Bypass Valve
Control System
Layout Drawing of Control System
Machine Monitor System
System Diagram of Machine Monitor System
Function of Machine Monitor System
KOMTRAX Plus System
System Diagram of KOMTRAX Plus System
Function of KOMTRAX Plus System
Component Parts of Control System
Machine Monitor
KOMTRAX Terminal
KOMTRAX Plus Controller
Wireless LAN Unit
Power Train Controller
Work Equipment Controller
Engine Controller
Option Controller
Fuel Feed Pump
Fuel Feed Pump Switch
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Structure of CLSS
Function of CLSS
Component Parts of Hydraulic System
Hydraulic Tank
Work Equipment Pump
LS Valve
PTO, Transmission Lubrication Pump, and Power Train Pump
Control Valve
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
Transmission, Steering, and Brake Control
Layout Drawing of Transmission, Steering, and Brake Control System (Machine with FCCS)
Function of Transmission, Steering, and Brake Control System (Machine with FCCS)
Layout Drawing of Transmission, Steering, and Brake Control System (Machine with PCCS)
Function of Transmission, Steering, and Brake Control System (Machine with PCCS)
Palm Command Control System
Palm Command Control System Diagram
Centralized Pressure Pickup Port
Layout Drawing of Centralized Pressure Pickup Port
Function of Centralized Pressure Pickup Port
Component Parts of Power Train System
Universal Joint
Power Train Mount
Torque Converter and PTO
Torque Converter Control Valve
Lockup Clutch ECMV
Stator Clutch ECMV
Transmission
Transmission ECMV
Main Relief Valve and Torque Converter Relief Valve
Transmission Lubrication Relief Valve
Transfer and Bevel Pinion
Bevel Gear Shaft, Steering Clutch, and Brake
Final Drive
Scavenging Pump
Electric Steering Lever
Work Equipment System
Work Equipment Control
Layout Drawing of Work Equipment Control
Function of Work Equipment System
Layout Drawing of Front Work Equipment
Layout Drawing of Variable Giant Ripper
Layout Drawing of Variable Multi-Shank Ripper
Shoe Slip Control System
Function of Shoes Slip Control System
Component Parts of Work Equipment System
Self-Pressure Reducing Valve
Work Equipment Lock Solenoid Valve
Pilot Circuit Accumulator
Quick Drop Valve
Piston Valve
Electric Blade Control Lever
Ripper Electric Lever
Pin Puller Switch
ICT System
Layout Drawing of ICT System
System Diagram of ICT Control System
Blade Control System
Function of Blade Control System
Leveling Mode System Diagram
Function of Leveling Mode
Operation of Leveling Mode
Dozing Mode System Diagram
Function of Dozing Mode
Operation of Dozing Mode
Smooth Start System
Smooth Start System Diagram
Function of Smooth Start System
Operation of Smooth Start System
Slip Control System
Slip Control System Diagram
Function of Slip Control System
Operation of Slip Control System
Assist Control System
Assist Control System Diagram
Function of Assist Control System
Operation of Assist Control System
Straight Travel Correction System
Straight Travel Correction System Diagram
Function of Straight Travel Correction System
Operation of Straight Travel Correction System
Smooth Carry System
Smooth Carry System Diagram
Function of Smooth Carry System
Operation of Smooth Carry System
Component Parts of ICT System
Navigation Controller
Control Box
AUX BOX
IMU Sensor
Stroke and Reset Sensor for Blade Lift Cylinder
Lifting System
Power Ladder System
Layout Drawing of Power Ladder System
Hydraulic Circuit Diagram of Power Ladder System
Function of Power Ladder System
Component Parts of Lifting System
Switch Box
Power Ladder Limit Switch Part
Control Valve Assembly
Undercarriage and Frame
Main Frame
Structure of Main Frame
Suspension
Structure of Suspension
Function of Suspension
Track Frame and Idler Cushion
Structure of Track Frame and Idler Cushion
Specifications of Track Frame and Idler Cushion
Function of Track Frame and Idler Cushion
Work Equipment
Structure of Front Work Equipment
Structure of Cylinder Stay
Structure of Variable Giant Ripper
Structure of Variable Multi-Shank Ripper
CAB Related Parts
ROPS
Structure of ROPS
Function of ROPS
CAB
Structure of CAB
CAB Mount
Structure of CAB Mount
Function of CAB Mount
20 Standard Value Table
Table of Contents
Standard Value Table for Engine
Standard Value Table for Engine: D375A-8R
Standard Value Table for Engine: D375AI-8R
Standard Value Table for Machine
Standard Value Table for Machine: D375A-8R
Standard Value Table for Machine: D375AI-8R
Machine Posture and Procedures to Measure Performance
30 Testing and Adjusting
Table of Contents
Precautions Before Work
Differences In Machine Monitor Symbols
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
How to Examine Engine Speed
Examine Boost Pressure
How to Examine Boost Pressure on Machine Monitor
How to Examine Boost Pressure by Testing Tool
Examine Exhaust Gas Temperature
How to Examine Exhaust Gas Temperature by Machine Monitor
How to Examine Exhaust Temperature by Testing Tools
Examine Exhaust Gas Color
How to Examine Exhaust Gas Color with Handy Smoke Checker
How to Examine Exhaust Gas Color with Smoke Meter
Examine and Adjust Valve Clearance
How to Examine Valve Clearance
How to Adjust Valve Clearance
Examine Compression Pressure
How to Examine Compression Pressure
Examine Blowby Pressure
How to Examine Blowby Pressure
Examine Engine Oil Pressure
How to Examine Engine Oil Pressure on Machine Monitor
How to Examine Engine Oil Pressure by Testing Tool
Examine Fuel Pressure
How to Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
How to Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
How to Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
How to Examine Fuel System for Leakage
Examine Supply Pump
How to Examine Supply Pump
Handle Cylinder Cut-out Mode Operation
Handle No-Injection Cranking Operation
Write Injector Compensation Value to Engine Controller
How to Write Injector Compensation Value
Adjust Decelerator Pedal
How to Adjust Decelerator Pedal
Power Train
Examine Power Train Oil Pressure
How to Examine Power Train Oil Pressure
Adjust Transmission Output Shaft Speed Sensor
How to Adjust Transmission Output Shaft Speed Sensor
Examine Brake Performance Simply
How to Examine Brake Performance Simply
Examine and Adjust Brake Pedal
How to Examine Brake Pedal
How to Adjust Brake Pedal
Move Machine by Parking Brake Release When Machine Does Not Travel
Move Machine with Hydraulic Type Parking Brake Release System
Move Machine with Electric Type Parking Brake Release System
Undercarriage and Frame
Examine and Adjust Track Tension
How to Examine Track Tension
How to Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
How to Release Remained Pressure in Hydraulic System
Examine and Adjust Work Equipment Oil Pressure
How to Examine Work Equipment Oil Pressure
How to Adjust Work Equipment Oil Pressure
Examine Oil Pressure of Control Circuit
How to Examine Oil Pressure in Control Circuit
Examine Work Equipment Lock Solenoid Valve Outlet Pressure
How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure
How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure
Bleed Air from Work Equipment Pump
How to Bleed Air from Work Equipment Pump
Examine Cooling Fan Speed
How to Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
How to Examine Cooling Fan Circuit Oil Pressure
Bleed Air in Cooling Fan Pump
How to Bleed Air in Cooling Fan Pump
Examine Parts Which Cause Hydraulic Drift of Work Equipment
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder
How to Examine Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder
Examine Oil Leakage from Work Equipment Cylinder
How to Examine Internal Oil Leakage of Work Equipment Cylinder
Bleed Air from Work Equipment Cylinder
How to Bleed Air from Work Equipment Cylinder
Operation When Work Equipment is Disabled
How to Operate When Work Equipment is Disabled
Power Ladder
Bleed Air from Power Ladder Cylinder
Bleed Air in Power Ladder Cylinder
Examine and Adjust Power Ladder Limit Switch
How to Examine and Adjust Power Ladder Limit Switch
How to Adjust Power Ladder Limit Switch
Work Equipment
Examine and Adjust Play of Blade Electric Lever
How to Examine Play of Blade Electric Lever
How to Adjust Play of Blade Electric Lever
How to Replace Universal Joint
CAB Related Parts
Examine and Adjust Operator Cab
How to Examine Operator Cab
Adjust Operator Cab
Adjust Play of Operator Seat
How to Adjust Play of Operator Seat
Examine Seating Switch
How to Examine Seating Switch
Electrical System
Set and Operate Machine Monitor
Operator Mode
Function to Show Technician Identification Status Screen
Function to Show Operator Identification Input Screen
Examine Function by LCD (Liquid Crystal Display)
Examine Function of Service Meter
How to Set Usage Limitation and Change Maintenance Password
Service Mode
How to Operate Service Mode
How to See Pre-defined Monitoring Information
How to Examine Self-Define Monitor Information
Abnormality Record Menu
How to See Maintenance Record
Maintenance Mode Setting
How to Set Phone Number Entry
Default Menu
Diagnostic Tests Menu
Adjustment Menu
No-Injection Cranking Operation
KOMTRAX Settings Menu
How to Show Service Message
How to Operate Snap Shot
How to Start Up KOMTRAX Terminal
Default Setting of KOMTRAX Plus Controller
How to do the Default Setting of KOMTRAX Plus Controller
Default Setting of Wireless LAN Modem
Default Setting of Wireless LAN Modem
How to Examine Wireless LAN Modem Communication
Download Data from KOMTRAX Plus Controller
How to Download Data from KOMTRAX Plus Controller
Adjust After Replacement of KOMTRAX Plus Controller
How to Adjust After Replacement of KOMTRAX Plus Controller
Adjust After Replacement of Wireless LAN Modem
How to Adjust After Replacement of Wireless LAN Modem
Adjust Rearview Camera Angle
How to Adjust Rearview Camera Angle
Set Region of Bluetooth(R) Compatible Radio
How to Set Region of Bluetooth(R) Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Handle Battery Isolator and Starting Motor Isolator
Examine Diodes
How to Examine Diodes by Digital Tester
How to Examine Diodes by Analog Tester
ICT System
Set and Operate Control Box
Examine and Adjust ICT Related Devices
Calibrate Blade Edge Position
How to Operate Blade Calibration Menu (Machine Cal Step A)
How to Operate Blade Calibration Menu (Machine Cal Step B)
Calibrate IMU Sensor
How to Calibrate IMU Sensor
Reset Cylinder Stroke End
Reset Lift Cylinder Stroke End
Set Standard Angle of Blade Edge
How to Input Wear Volume of Blade Edge and Track Shoes
Examine and Adjust Blade Elevation
Examine Blade Elevation
Adjust Blade Elevation
Examine Stroke Sensor for Lift Cylinder
How to Examine Stroke Sensor for Lift Cylinder
Examine and Adjust Reset Sensor for Lift Cylinder
How to Examine Reset Sensor for Lift Cylinder
How to Adjust Reset Sensor for Lift Cylinder
Adjust When Work Equipment Controller is Replaced
How to Adjust When Work Equipment Controller is Replaced
Adjust When ICT Related Devices are Repaired or Replaced
Pm Clinic
Pm Clinic Service
Pm Clinic Check Sheet: D375A-8R
Pm Clinic Check Sheet: D375AI-8R
Pm Clinic Check Sheet for Undercarriage: D375A-8R
Pm Clinic Check Sheet for Undercarriage: D375AI-8R
Perform Quick Pm
How to Perform Quick Pm
40 Troubleshooting
Table of Contents
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Sequence of Events in Troubleshooting
Inspection Before Troubleshooting
Inspection Procedure Before Troubleshooting
Walk-around Check
Inspection in Accordance with Inspection Procedure
How to Drain Water and Sediment from Fuel Tank
How to Examine Water Separator, Drain Water and Sediment
Examine Fuel Main Filter
How to Examine Oil Level in Hydraulic Tank, Add Oil
How to Examine Coolant Level and Add Coolant
How to Examine Oil Level in Engine Oil Pan, Add Oil
Examine Oil Level in Power Train Case, Add Oil
How to Examine Dust Indicator
How to Examine Brake Operation
How to Examine Electric Wiring
How to Examine Fuel Level and Add Fuel
How to Examine Operation of Lamps
How to Examine Machine Monitor
How to Remove Sediment in Engine Room
How to Examine Operation State of Horn
How to Examine Operation State of Backup Alarm
How to Examine Electrical Components
How to Connect Adapter for Troubleshooting Controller
How to Connect Adapter for Troubleshooting Machine Monitor
How to Connect Adapter for Troubleshooting Work Equipment Controller
How to Connect Adapter for Troubleshooting Power Train Controller
How to Connect Adapter to Troubleshoot KOMTRAX Terminal
How to Connect Adapter to Troubleshoot KOMTRAX Plus Controller
How to Connect Adapter for Troubleshooting of Option Controller
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting
How to Diagnose Wiring Harness for Open Circuit of Pressure Sensor System
Connector List and Layout
Connector Layout (1)
Connector Layout (2)
Connector Layout (3)
Connector Layout (4)
Connector Layout (5)
Connector Layout (6)
Connector Layout (7)
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Failure Code [1500L0]
Failure Code [15B0NX]
Failure Code [15SAL1]
Failure Code [15SALH]
Failure Code [15SBL1]
Failure Code [15SBLH]
Failure Code [15SEL1]
Failure Code [15SELH]
Failure Code [15SFL1]
Failure Code [15SFLH]
Failure Code [15SGL1]
Failure Code [15SGLH]
Failure Code [15SJL1]
Failure Code [15SJLH]
Failure Code [1800MW]
Failure Code [2201L1]
Failure Code [2201LH]
Failure Code [2202L1]
Failure Code [2202LH]
Failure Code [2300NR]
Failure Code [2301L1]
Failure Code [2301LH]
Failure Code [2301NR]
Failure Code [2301NT]
Failure Code [2302L1]
Failure Code [2302LH]
Failure Code [2302NR]
Failure Code [2302NT]
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
Failure Code [989L00]
Failure Code [989M00]
Failure Code [989N00]
Failure Code [A900FR]
Failure Code [A900N6]
Failure Code [A900NY]
Failure Code [AA10NX]
Failure Code [AB00KE]
Failure Code [B@BAZG]
Failure Code [B@BAZK]
Failure Code [B@BCNS]
Failure Code [B@BCQA]
Failure Code [B@BCZK]
Failure Code [B@CENS]
Failure Code [B@HANS]
Failure Code [B@HAZK]
Failure Code [CA115]
Failure Code [CA122]
Failure Code [CA123]
Failure Code [CA131]
Failure Code [CA132]
Failure Code [CA135]
Failure Code [CA141]
Failure Code [CA144]
Failure Code [CA145]
Failure Code [CA153]
Failure Code [CA154]
Failure Code [CA212]
Failure Code [CA213]
Failure Code [CA221]
Failure Code [CA222]
Failure Code [CA234]
Failure Code [CA238]
Failure Code [CA239]
Failure Code [CA271]
Failure Code [CA272]
Failure Code [CA273]
Failure Code [CA274]
Failure Code [CA322]
Failure Code [CA323]
Failure Code [CA324]
Failure Code [CA325]
Failure Code [CA331]
Failure Code [CA332]
Failure Code [CA343]
Failure Code [CA351]
Failure Code [CA352]
Failure Code [CA386]
Failure Code [CA428]
Failure Code [CA429]
Failure Code [CA441]
Failure Code [CA442]
Failure Code [CA449]
Failure Code [CA451]
Failure Code [CA452]
Failure Code [CA515]
Failure Code [CA516]
Failure Code [CA553]
Failure Code [CA559]
Failure Code [CA689]
Failure Code [CA691]
Failure Code [CA692]
Failure Code [CA697]
Failure Code [CA698]
Failure Code [CA731]
Failure Code [CA778]
Failure Code [CA1117]
Failure Code [CA1135]
Failure Code [CA1257]
Failure Code [CA1843]
Failure Code [CA1844]
Failure Code [CA1942]
Failure Code [CA2185]
Failure Code [CA2186]
Failure Code [CA2249]
Failure Code [CA2765]
Failure Code [CA4952]
Failure Code [CB115]
Failure Code [CB238]
Failure Code [CB239]
Failure Code [CB271]
Failure Code [CB272]
Failure Code [CB273]
Failure Code [CB274]
Failure Code [CB343]
Failure Code [CB352]
Failure Code [CB386]
Failure Code [CB441]
Failure Code [CB442]
Failure Code [CB689]
Failure Code [CB697]
Failure Code [CB698]
Failure Code [CB731]
Failure Code [CB778]
Failure Code [CB1117]
Failure Code [CB1257]
Failure Code [CB4952]
Failure Code [D107KA]
Failure Code [D107KB]
Failure Code [D107KY]
Failure Code [D130KA]
Failure Code [D130KB]
Failure Code [D182KZ]
Failure Code [D19JKZ]
Failure Code [D1D5KA]
Failure Code [D1D5KB]
Failure Code [D1D5KY]
Failure Code [D1EFKA]
Failure Code [D1EFKB]
Failure Code [D1EWKA]
Failure Code [D1EWKB]
Failure Code [D1EWKY]
Failure Code [D1EXKA]
Failure Code [D1EXKB]
Failure Code [D1EXMC]
Failure Code [D862KA]
Failure Code [DAF0MB]
Failure Code [DAF0MC]
Failure Code [DAF8KB]
Failure Code [DAF9KQ]
Failure Code [DAFGMC]
Failure Code [DAFLKA]
Failure Code [DAFLKB]
Failure Code [DAFQKR]
Failure Code [DAQW00]
Failure Code [DAZ9KQ]
Failure Code [DAZQKR]
Failure Code [DB2QKR]
Failure Code [DB2RKR]
Failure Code [DB90KT]
Failure Code [DB90MC]
Failure Code [DB91KK]
Failure Code [DB92KK]
Failure Code [DB92KT]
Failure Code [DB95KK]
Failure Code [DB97KK]
Failure Code [DB99KQ]
Failure Code [DB9LKA]
Failure Code [DB9LKB]
Failure Code [DB9QKR]
Failure Code [DB9RKR]
Failure Code [DBBUKM]
Failure Code [DBBUKR]
Failure Code [DBE0KT]
Failure Code [DBE0MC]
Failure Code [DBE1KK]
Failure Code [DBE2KK]
Failure Code [DBE2KT]
Failure Code [DBE5KK]
Failure Code [DBE6KK]
Failure Code [DBE7KK]
Failure Code [DBE9KQ]
Failure Code [DBELKA]
Failure Code [DBELKB]
Failure Code [DBEQKR]
Failure Code [DBERKR]
Failure Code [DBU0KR]
Failure Code [DBUSKR]
Failure Code [DBUTKA]
Failure Code [DBUTKN]
Failure Code [DBV0MC]
Failure Code [DBV1KK]
Failure Code [DBV6KB]
Failure Code [DBVLKA]
Failure Code [DBVLKB]
Failure Code [DBVQKR]
Failure Code [DBVRKR]
Failure Code [DBVVKR]
Failure Code [DBVWKR]
Failure Code [DD12KA]
Failure Code [DD12KB]
Failure Code [DD13KA]
Failure Code [DD13KB]
Failure Code [DD14KA]
Failure Code [DD14KB]
Failure Code [DDDDKA]
Failure Code [DDDDKB]
Failure Code [DDDDKX]
Failure Code [DDDHKB]
Failure Code [DDDKKA]
Failure Code [DDDKKB]
Failure Code [DDDLKA]
Failure Code [DDDLKB]
Failure Code [DDE2KA]
Failure Code [DDE9KA]
Failure Code [DDE9KB]
Failure Code [DDK4KA]
Failure Code [DDK4KB]
Failure Code [DDT5KQ]
Failure Code [DDKAKA]
Failure Code [DDKAKB]
Failure Code [DDKBKA]
Failure Code [DDKBKB]
Failure Code [DDKCL4]
Failure Code [DDKEL4]
Failure Code [DDKHKA]
Failure Code [DDKHKB]
Failure Code [DDKQKA]
Failure Code [DDKQKB]
Failure Code [DDKRKA]
Failure Code [DDKRKB]
Failure Code [DDKSKA]
Failure Code [DDKSKB]
Failure Code [DDN7L4]
Failure Code [DDN8L4]
Failure Code [DDNLKA]
Failure Code [DDNLKB]
Failure Code [DDTSL1]
Failure Code [DDTSLH]
Failure Code [DFA4KX]
Failure Code [DFA4KZ]
Failure Code [DFA4L8]
Failure Code [DFA5KA]
Failure Code [DFA5KY]
Failure Code [DFA6KA]
Failure Code [DFA6KY]
Failure Code [DFA7KX]
Failure Code [DFA7KZ]
Failure Code [DFA7L8]
Failure Code [DFA8KA]
Failure Code [DFA8KY]
Failure Code [DFA9KA]
Failure Code [DFA9KY]
Failure Code [DFAAKX]
Failure Code [DFAAKZ]
Failure Code [DFAAL8]
Failure Code [DFABKA]
Failure Code [DFABKY]
Failure Code [DFACKA]
Failure Code [DFACKY]
Failure Code [DFADKX]
Failure Code [DFADKZ]
Failure Code [DFADL8]
Failure Code [DFAEKA]
Failure Code [DFAEKY]
Failure Code [DFAFKA]
Failure Code [DFAFKY]
Failure Code [DGS1KA]
Failure Code [DGS1KX]
Failure Code [DGT1KA]
Failure Code [DGT1KX]
Failure Code [DGT5KY]
Failure Code [DGT5KZ]
Failure Code [DGT6KY]
Failure Code [DGT6KZ]
Failure Code [DH21KA]
Failure Code [DH21KY]
Failure Code [DHA4KA]
Failure Code [DHT2L6]
Failure Code [DHT3KX]
Failure Code [DHT5KA]
Failure Code [DHT5KY]
Failure Code [DHT7KA]
Failure Code [DHT7KY]
Failure Code [DHZ1KX]
Failure Code [DK10KA]
Failure Code [DK10KB]
Failure Code [DK30KA]
Failure Code [DK30KX]
Failure Code [DK30KY]
Failure Code [DK30KZ]
Failure Code [DK30L8]
Failure Code [DK31KA]
Failure Code [DK31KY]
Failure Code [DK40KA]
Failure Code [DK40KY]
Failure Code [DK55KX]
Failure Code [DK55KZ]
Failure Code [DK55L8]
Failure Code [DK56KA]
Failure Code [DK56KY]
Failure Code [DK57KA]
Failure Code [DK57KY]
Failure Code [DK60KA]
Failure Code [DK60KY]
Failure Code [DK80KR]
Failure Code [DK80KT]
Failure Code [DKH1KA]
Failure Code [DKH1KY]
Failure Code [DKW0KX]
Failure Code [DKW0KZ]
Failure Code [DKW0L8]
Failure Code [DKW1KA]
Failure Code [DKW1KY]
Failure Code [DKW2KA]
Failure Code [DKW2KY]
Failure Code [DKW3KX]
Failure Code [DKW3KZ]
Failure Code [DKW3L8]
Failure Code [DKW4KA]
Failure Code [DKW4KY]
Failure Code [DKW5KA]
Failure Code [DKW5KY]
Failure Code [DKSGL8]
Failure Code [DKSHKA]
Failure Code [DKSHKB]
Failure Code [DKSJKA]
Failure Code [DKSJKB]
Failure Code [DKSKKA]
Failure Code [DKSKKB]
Failure Code [DKSKMB]
Failure Code [DKSLL8]
Failure Code [DKSMKA]
Failure Code [DKSMKB]
Failure Code [DKSNKA]
Failure Code [DKSNKB]
Failure Code [DKSPKA]
Failure Code [DKSPKB]
Failure Code [DKSPMB]
Failure Code [DLM3KA]
Failure Code [DLM3MB]
Failure Code [DLT3KA]
Failure Code [DLT3KB]
Failure Code [DNDAMC]
Failure Code [DNDBKA]
Failure Code [DNDBKB]
Failure Code [DNDCKA]
Failure Code [DNDCKB]
Failure Code [DNDDKA]
Failure Code [DNDDKB]
Failure Code [DNDEKA]
Failure Code [DNDEKB]
Failure Code [DR21KX]
Failure Code [DR31KX]
Failure Code [DV20KB]
Failure Code [DW4BKA]
Failure Code [DW4BKB]
Failure Code [DW7BKA]
Failure Code [DW7BKB]
Failure Code [DWN3KA]
Failure Code [DWN3KB]
Failure Code [DWN3KY]
Failure Code [DWN5KA]
Failure Code [DWN5KB]
Failure Code [DWN5KY]
Failure Code [DWNCKA]
Failure Code [DWNCKB]
Failure Code [DWNCKY]
Failure Code [DWNVKA]
Failure Code [DWNVKB]
Failure Code [DWNWKA]
Failure Code [DWNWKB]
Failure Code [DWNXKA]
Failure Code [DWNXKB]
Failure Code [DWNYKA]
Failure Code [DWNYKB]
Failure Code [DXH1KA]
Failure Code [DXH1KB]
Failure Code [DXH1KY]
Failure Code [DXH4KA]
Failure Code [DXH4KB]
Failure Code [DXH4KY]
Failure Code [DXH5KA]
Failure Code [DXH5KB]
Failure Code [DXH5KY]
Failure Code [DXH6KA]
Failure Code [DXH6KB]
Failure Code [DXH6KY]
Failure Code [DXH7KA]
Failure Code [DXH7KB]
Failure Code [DXH7KY]
Failure Code [DXH8KA]
Failure Code [DXH8KB]
Failure Code [DXH8KY]
Failure Code [DXH9KA]
Failure Code [DXH9KB]
Failure Code [DXH9KY]
Failure Code [DXHAKA]
Failure Code [DXHAKB]
Failure Code [DXHAKY]
Failure Code [DXHBKA]
Failure Code [DXHBKB]
Failure Code [DXHBKY]
Failure Code [DXHCKA]
Failure Code [DXHCKB]
Failure Code [DXHCKY]
Failure Code [DXHRKA]
Failure Code [DXHRKB]
Failure Code [DXHRKY]
Failure Code [DXHSKA]
Failure Code [DXHSKB]
Failure Code [DXHSKY]
Failure Code [DXHTKA]
Failure Code [DXHTKB]
Failure Code [DXHTKY]
Failure Code [DXHUKA]
Failure Code [DXHUKB]
Failure Code [DXHUKY]
Failure Code [DXHWKA]
Failure Code [DXHWKB]
Failure Code [DXHWKY]
Failure Code [DXHXKA]
Failure Code [DXHXKB]
Failure Code [DXHXKY]
Failure Code [DXHYKA]
Failure Code [DXHYKB]
Failure Code [DXHYKY]
Failure Code [DXHZKA]
Failure Code [DXHZKB]
Failure Code [DXHZKY]
Failure Code [DXJ4KA]
Failure Code [DXJ4KB]
Failure Code [DXJ8KA]
Failure Code [DXJ8KB]
Failure Code [DXJ8KY]
Failure Code [DXJ9KA]
Failure Code [DXJ9KB]
Failure Code [DXJ9KY]
Failure Code [DXJBKA]
Failure Code [DXJBKB]
Failure Code [DXJBKY]
Failure Code [DY2HKA]
Failure Code [F7A0KT]
Failure Code [F7A1KK]
Failure Code [F7A8KB]
Failure Code [F7ALKA]
Failure Code [F7ALKB]
Failure Code [F7AQKR]
Failure Code [F7ARKR]
Failure Code [F7ASKA]
Failure Code [F7BSKR]
Failure Code [F7BTKR]
Failure Code [F7C0KR]
Failure Code [F7CRKT]
Failure Code [F7FQKR]
Failure Code [F9A0KT]
Failure Code [F9A0MC]
Failure Code [F9A1KK]
Failure Code [F9A2KK]
Failure Code [F9A2KY]
Failure Code [F9AQKR]
Failure Code [F9ARKR]
Failure Code [F9ATKA]
Failure Code [F9ATKB]
Failure Code [F9AUMC]
Failure Code [F@BWNR]
Failure Code [F@BWNS]
Failure Code [F@BXNR]
Failure Code [F@BXNS]
Troubleshooting of Electrical System (E-Mode)
E-1 Engine Does Not Start (Engine Does Not Crank)
E-2 Manual Preheating System Does Not Operate
E-3 Automatic Preheating System Does Not Operate
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature
E-14 Fuel Gauge Does Not Show Normally
E-15 Power Train Oil Temperature Gauge Does Not Show Correct Temperature
E-16 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature
E-17 Operation Mode Does Not Change
E-18 Gear Shift Mode Does Not Change
E-19 Operating Customize Switch Does Not Display Customize Screen
E-20 Modifying Setting on Customize Screen Does Not Change Setting of Machine
E-21 Some Areas of Machine Monitor Screen are Not Shown
E-22 Alarm Buzzer Does Not Sound or Cannot be Stopped
E-23 Service Meter is Not Shown While Starting Switch is in OFF Position
E-24 Machine Does Not Change to Service Mode
E-25 Horn Does Not Sound
E-26 Horn Does Not Stop
E-27 Backup Alarm Does Not Sound
E-28 Backup Alarm Does Not Stop Operation
E-29 Headlamp Does Not Come On
E-30 Rear Lamp and Ripper Point Lamp Do Not Come On
E-31 No Wiper Operates
E-32 Front Wiper Does Not Operate
E-33 Rear Wiper Does Not Operate
E-34 Left Door Wiper Does Not Operate
E-35 Right Door Wiper Does Not Operate
E-36 Fuel Feed Pump Does Not Operate or Stop Automatically
E-37 Fan Does Not Rotate in Reverse
E-38 Gear Cannot be Shifted
E-39 Front Washer Does Not Operate
E-40 Rear Washer Does Not Operate
E-41 Left Door Washer Does Not Operate
E-42 Right Door Washer Does Not Operate
E-43 Ripper Pin Puller Does Not Work
E-44 KOMTRAX Plus System Does Not Operate Normally
E-45 Cannot Download Data with Wireless LAN
E-46 Operator Not Present Monitor Does Not Show Correctly
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)
Information Shown in Troubleshooting Table (H-Mode)
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull)
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed)
H-3 Machine Does Not Move Off at All Gear Speeds
H-4 Machine Travels Only in One Direction, Forward or in Reverse
H-5 Large Time Lag is in Gear Shifting or Directional Change
H-6 Brake Does Not Work
H-7 Power Train Oil Overheats
H-8 Torque Converter Lockup Clutch Does Not Engage
H-9 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT)
H-10 Machine Can Turn (Steering) Only in One Direction
H-11 Machine Falls Over Too Much (Steering)
H-12 All Work Equipment Operate Slowly
H-13 All Work Equipment Do Not Operate
H-14 Blade Lift Speed or Power is Low
H-15 Blade Tilt Speed or Power is Low
H-16 Ripper Lift Speed or Power is Low
H-17 Ripper Tilt Speed or Power is Low
H-18 Hydraulic Drift of Blade Lift is Large
H-19 Hydraulic Drift of Tilted Blade is Large
H-20 Hydraulic Drift of Lifted Ripper is Large
H-21 Ripper Pin Puller Cylinder Does Not Operate
H-22 Blade Pitch Cylinder Does Not Operate
H-23 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve
H-24 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)
H-25 Seismic Isolation Operator Seat Shakes Abnormally or Receives Shock
Troubleshooting of Engine (S-Mode)
Information Shown in Troubleshooting Table (S-Mode)
S-1 Engine Does Not Crank When Starting Switch is Turned to START Position
S-2 Engine Cranks but No Exhaust Smoke Comes Out
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
S-4 Engine Startability is Unsatisfactory
S-5 Engine Does Not Pick Up Smoothly
S-6 Engine Stops During Operation
S-7 Engine Runs Rough or is Not Stable
S-8 Engine Lacks Power
S-9 Engine Oil Consumption is Excessive
S-10 Oil Becomes Dirty Quickly
S-11 Fuel Consumption is Excessive
S-12 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
S-13 Oil Pressure Drops
S-14 Fuel Mixes Into Engine Oil
S-15 Water Mixes Into Engine Oil (Milky)
S-16 Coolant Temperature Increases Too High (Overheat)
S-17 There is an Unusual Noise
S-18 Vibration is Excessive
S-19 Air Cannot be Bled from Fuel Circuit
50 Disassembly and Assembly
Table of Contents
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Prepare
Drain and Add Coolant
How to Drain Coolant
How to Add Coolant
Drain and Add Hydraulic Oil
How to Drain Hydraulic Oil
How to Add Hydraulic Oil
Drain and Add Fuel
How to Drain Fuel
How to Add Fuel
Collect and Refill Refrigerant
How to Collect Refrigerant
How to Refill Refrigerant
Engine and Cooling System
Remove and Install Supply Pump Assembly
How to Remove Supply Pump Assembly
How to Install Supply Pump Assembly
Remove and Install Injector Assembly
How to Remove Injector Assembly
How to Install Injector Assembly
Remove and Install Cylinder Head Assembly
How to Remove Cylinder Head Assembly
How to Install Cylinder Head Assembly
Remove and Install Common Rail
Remove Common Rail
How to Install Common Rail
Remove and Install Starting Motor Assembly
How to Remove Starting Motor Assembly
How to Install Starting Motor Assembly
Remove and Install Radiator Guard Assembly
How to Remove Radiator Guard Assembly
How to Install Radiator Guard Assembly
Remove and Install Cooling Assembly
How to Remove Cooling Assembly
How to Install Cooling Assembly
Remove and Install Radiator Assembly
How to Remove Radiator Assembly
How to Install Radiator Assembly
Remove and Install Radiator Tube
How to Remove Radiator Tube
How to Install Radiator Tube
Remove and Install Hydraulic Oil Cooler Assembly
How to Remove Hydraulic Oil Cooler Assembly
How to Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
How to Remove Aftercooler Assembly
How to Install Aftercooler Assembly
Open and Close Cooling Fan Drive Assembly
How to Open Cooling Fan Drive Assembly
How to Close Cooling Fan Drive Assembly
Remove and Install Cooling Fan Drive Assembly
How to Remove Cooling Fan Drive Assembly
How to Install Cooling Fan Drive Assembly
Remove and Install Cooling Fan Motor Assembly
How to Remove Cooling Fan Motor Assembly
How to Install Cooling Fan Motor Assembly
Remove and Install Engine Assembly
How to Remove Engine Assembly
How to Install Engine Assembly
Remove and Install Engine Front Oil Seal
How to Remove Engine Front Oil Seal
How to Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
How to Remove Engine Rear Oil Seal
How to Install Engine Rear Oil Seal
Remove and Install Engine Hood Assembly
How to Remove Engine Hood Assembly
How to Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
How to Remove Fuel Tank Assembly
How to Install Fuel Tank Assembly
Remove and Install Muffler Assembly
How to Remove Muffler Assembly
How to Install Muffler Assembly
Remove and Install Turbo Charger Assembly
How to Remove Turbo Charger Assembly
How to Install Turbo Charger Assembly
Remove and Install Air Cleaner Bracket Assembly
How to Remove Air Cleaner Bracket Assembly
How to Install Air Cleaner Bracket Assembly
Remove and Install Air Cleaner Assembly
How to Remove Air Cleaner Assembly
How to Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
How to Remove Air Conditioner Compressor Assembly
How to Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
How to Remove Air Conditioner Condenser Assembly
How to Install Air Conditioner Condenser Assembly
Power Train
Remove and Install Damper Assembly
How to Remove Damper Assembly
How to Install Damper Assembly
Disassemble and Assemble Damper Assembly
How to Disassemble Damper Assembly
How to Assemble Damper Assembly
Remove and Install Power Train Unit Assembly
How to Remove Power Train Unit Assembly
How to Install Power Train Unit Assembly
Disconnect and Connect Power Train Unit Assembly
How to Disconnect Power Train Unit Assembly
How to Connect Power Train Unit Assembly
Disassemble and Assemble PTO Assembly
How to Disassemble PTO Assembly
How to Assemble PTO Assembly
Disassemble and Assemble Torque Converter Assembly
How to Disassemble Torque Converter Assembly
How to Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
How to Disassemble Transmission Assembly
How to Assemble Transmission Assembly
Disassemble and Assemble Steering Case Assembly
How to Disassemble Steering Case Assembly
How to Assemble Steering Case Assembly
Remove and Install Final Drive Assembly
How to Remove Final Drive Assembly
How to Install Final Drive Assembly
Disassemble and Assemble Final Drive Assembly
How to Disassemble Final Drive Assembly
How to Assemble Final Drive Assembly
Undercarriage and Frame
Remove and Install Track Frame Assembly
How to Remove Track Frame Assembly
How to Install Track Frame Assembly
Remove and Install Idler Assembly
How to Remove Idler Assembly
How to Install Idler Assembly
Disassemble and Assemble Idler Assembly
How to Disassemble Idler Assembly
How to Assemble Idler Assembly
Remove and Install Recoil Spring Assembly
How to Remove Recoil Spring Assembly
How to Install Recoil Spring Assembly
Disassemble and Assemble Recoil Spring Assembly
How to Disassemble Recoil Spring Assembly
How to Assemble Recoil Spring Assembly
Remove and Install Track Roller Assembly
How to Remove Track Roller Assembly
How to Install Track Roller Assembly
Disassemble and Assemble Track Roller Assembly
How to Disassemble Track Roller Assembly
How to Assemble Track Roller Assembly
Remove and Install No. 1 Bogie Assembly
How to Remove No.1 Bogie Assembly
How to Install No. 1 Bogie Assembly
Remove and Install Bogie Assembly
How to Remove Bogie Assembly
How to Install Bogie Assembly
Disassemble and Assemble Bogie Assembly
How to Disassemble Bogie Assembly
How to Assemble Bogie Assembly
Remove and Install Carrier Roller Assembly
How to Remove Carrier Roller Assembly
How to Install Carrier Roller Assembly
Disassemble and Assemble Carrier Roller Assembly
How to Disassemble Carrier Roller Assembly
How to Assemble Carrier Roller Assembly
Remove and Install Pivot Shaft Assembly
How to Remove Pivot Shaft Assembly
How to Install Pivot Shaft Assembly
Separate and Connect Track Assembly
How to Separate Track Assembly
How to Install Track Assembly
Disassemble and Assemble Track Assembly Generally
How to Disassemble Full Track Shoes Assembly
How to Assemble Full Track Shoes Assembly
Disassemble and Assemble One Track Link Assembly in Field
How to Disassemble One Track Link Assembly in Field
How to Assemble One Track Link Assembly in Field
Disassemble and Assemble Master Link
How to Disassemble Master Link
How to Assemble Master Link
Remove and Install Equalizer Bar Assembly
How to Remove Equalizer Bar Assembly
How to Install Equalizer Bar Assembly
Disassemble and Assemble Equalizer Bar Bushing
How to Disassemble Equalizer Bar Bushing
How to Assemble Equalizer Bar Bushing
Remove and Install Segment Teeth
How to Remove Segment Teeth
How to Install Segment Teeth
Remove and Install Power Ladder Assembly
Remove Power Ladder Assembly
How to Install Power Ladder Assembly
Open and Close Underguard Assembly
How to Open Underguard Assembly
How to Close Underguard Assembly
Remove and Install Under Guard Assembly
How to Remove Underguard Assembly
How to Install Underguard Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
How to Remove Hydraulic Tank Assembly
How to Install Hydraulic Tank Assembly
Remove and Install Work Equipment Pump Assembly
How to Remove Work Equipment Pump Assembly
How to Install Work Equipment Pump Assembly
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly
How to Remove Power Train Pump and Steering Lubrication Pump Assembly
How to Install Power Train Pump and Steering Lubrication Pump Assembly
Remove and Install Cooling Fan Pump Assembly
How to Remove Cooling Fan Pump Assembly
How to Install Cooling Fan Pump Assembly
Remove and Install Scavenging Pump Assembly
How to Remove Scavenging Pump Assembly
How to Install Scavenging Pump Assembly
Disassemble and Assemble Control Valve Assembly
How to Assemble Control Valve Assembly
Remove and Install Control Valve Assembly
How to Remove Control Valve Assembly
How to Install Control Valve Assembly
Work Equipment
Remove and Install Blade Assembly
How to Remove Blade Assembly
How to Install Blade Assembly
Disassemble and Assemble Blade Assembly
How to Disassemble Blade Assembly
How to Assemble Blade Assembly
Remove and Install Blade Lift Cylinder Assembly
How to Remove Blade Lift Cylinder Assembly
How to Install Blade Lift Cylinder Assembly
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly
How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly
How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly
Disassemble and Assemble Blade Lift Cylinder Assembly
How to Disassemble Blade Lift Cylinder Assembly
How to Assemble Blade Lift Cylinder Assembly
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly
How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly
How to Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly
Disassemble and Assemble Blade Tilt Cylinder Assembly
How to Disassemble Blade Tilt Cylinder Assembly
How to Assemble Blade Tilt Cylinder Assembly
Disassemble and Assemble Giant Ripper Assembly
How to Disassemble Giant Ripper Assembly
How to Assemble Giant Ripper Assembly
Disassemble and Assemble Ripper Pin Puller Cylinder Assembly
How to Disassemble Ripper Pin Puller Cylinder Assembly
How to Assemble Ripper Pin Puller Cylinder Assembly
CAB Related Parts
Remove and Install ROPS Guard
How to Remove ROPS Guard
How to Install ROPS Guard
Remove and Install Operator Cab Assembly
How to Remove Operator Cab Assembly
How to Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
How to Remove Operator Cab Glass (Adhered Glass)
How to Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
How to Remove Air Conditioner Unit Assembly
How to Install Air Conditioner Unit Assembly
Remove and Install Operator Seat
How to Remove Operator Seat
How to Install Operator Seat
How to Remove and Install Seat Belt
How to Remove Seat Belt
How to Install Seat Belt
Remove and Install FCCS
How to Remove FCCS
How to Install FCCS
Electrical System
Remove and Install Engine Controller Assembly
How to Remove Engine Controller Assembly
How to Install Engine Controller Assembly
Remove and Install Power Train Controller Assembly
How to Remove Power Train Controller Assembly
How to Install Power Train Controller Assembly
Remove and Install Work Equipment Controller Assembly
How to Remove Work Equipment Controller Assembly
How to Install Work Equipment Controller Assembly
Remove and Install Machine Monitor Assembly
How to Remove Machine Monitor Assembly
How to Install Machine Monitor Assembly
Remove and Install Intake Air Temperature Sensor
How to Remove Intake Air Temperature Sensor
How to Install Intake Air Temperature Sensor
Remove and Install Crankcase Pressure Sensor
Remove Crankcase Pressure Sensor
Install Crankcase Pressure Sensor
Remove and Install KOMTRAX Terminal Assembly
How to Remove KOMTRAX Terminal Assembly
How to Install KOMTRAX Terminal Assembly
Remove And Install KOMTRAX Plus Controller Assembly
How to Remove KOMTRAX Plus Controller Assembly
How to Install KOMTRAX Plus Controller Assembly
Remove and Install Wireless LAN Unit Assembly
How to Remove Wireless LAN Unit Assembly
How to Install Wireless LAN Unit Assembly
Remove and Install Control Box
How to Remove Control Box
How to Install Control Box
Remove and Install Option Controller Assembly
How to Remove Option Controller Assembly
How to Install Option Controller Assembly
Remove and Install Navigation Controller Assembly
How to Remove Navigation Controller Assembly
How to Install Navigation Controller Assembly
Remove and Install AUX BOX
How to Remove AUX BOX
How to Install AUX BOX
Remove and Install IMU Sensor
How to Remove IMU Sensor
How to Install IMU Sensor
60 Maintenance Standard
Table of Contents
Explanation of Terms for Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling System
Maintenance Standard for Cooling Fan Pump
Maintenance Standard for Servo Valve
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Universal Joint
Maintenance Standard for Power Train Mount
Maintenance Standard for Torque Converter and PTO
Maintenance Standard for Torque Converter Control Valve
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for Stator Clutch ECMV
Maintenance Standard for Transmission
Maintenance Standard for PTO, Transmission Lubrication Pump, and Power Train Pump
Maintenance Standard for Transmission ECMV
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve
Maintenance Standard for Transmission Lubrication Relief Valve
Maintenance Standard for Transfer, Bevel Gear Shaft, and Steering
Maintenance Standard for Brake Solenoid Valve
Maintenance Standard for Sudden Stop Prevention Valve
Maintenance Standard for Final Drive
Maintenance Standard for Sprocket for Conventional Type Track Shoes
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes
Undercarriage and Frame
Maintenance Standard for Main Frame
Maintenance Standard for Suspension
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller Bogie
Maintenance Standard for Track Roller for Conventional Type Track Shoes
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes
Maintenance Standard for Conventional Type Track Shoes
Maintenance Standard for Single Shoes and Heavy Duty Shoes
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Work Equipment Pump
Maintenance Standard for Scavenging Pump
Maintenance Standard for Control Valve
Maintenance Standard for Self-Pressure Reducing Valve
Maintenance Standard for Quick Drop Valve
Work Equipment
Maintenance Standard for Cylinder Stay
Maintenance Standard for Front Work Equipment
Maintenance Standard for Cutting Edge and End Bit
Maintenance Standard for Blade Lift Cylinder
Maintenance Standard for Blade Tilt Cylinder
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder
Maintenance Standard for Variable Multi-Shank Ripper
Maintenance Standard for Variable Giant Ripper
Maintenance Standard for Ripper Lift Cylinder
Maintenance Standard for Ripper Tilt Cylinder
Maintenance Standard for Pin Puller Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount
Maintenance Standard for ROPS
80 Appendix
Table of Contents
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Configuration Diagram of Air Conditioner Unit
Function of Air Conditioner Unit
Component Parts of Air Conditioner Unit
Function of Evaporator as Air Conditioner Unit Component
Function of Heater Core as Air Conditioner Unit Component
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component
Function of Servo Motor as Air Conditioner Unit Component
Structure of Expansion Valve as Air Conditioner Unit Component
Function of Expansion Valve as Air Conditioner Unit Component
Operate Expansion Valve as Air Conditioner Unit Component
Function of Triple Pressure Switch
Air Conditioner Controller
Structure of Air Conditioner Controller
Compressor
Structure of Compressor
Specifications of Compressor
Function of Compressor
Condenser
Structure of Condenser
Specifications of Condenser
Function of Condenser
Receiver Drier
Structure of Receiver Dryer
Specifications of Receiver Dryer
Function of Receiver Dryer
Air Conditioner Related Sensors
Structure of Sunlight Sensor
Function of Sunlight Sensor
Structure of Outside Temperature Sensor
Function of Outside Air Temperature Sensor
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Function of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct)
How to Examine Air Leakage (Duct)
Examine Air Conditioner with Self-Diagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Refrigerant (Triple) Pressure Switch
How to Examine Refrigerant (Triple) Pressure Switch
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart 1
Air Conditioner Troubleshooting Chart 2
Information Shown in Troubleshooting Table
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
90 Circuit Diagrams
Table of Contents
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram
Power Train Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram
Electrical Circuit Diagram (1/16)
Electrical Circuit Diagram (2/16)
Electrical Circuit Diagram (3/16)
Electrical Circuit Diagram (4/16)
Electrical Circuit Diagram (5/16)
Electrical Circuit Diagram (6/16)
Electrical Circuit Diagram (7/16)
Electrical Circuit Diagram (8/16)
Electrical Circuit Diagram (9/16)
Electrical Circuit Diagram (10/16)
Electrical Circuit Diagram (11/16)
Electrical Circuit Diagram (12/16)
Electrical Circuit Diagram (13/16)
Electrical Circuit Diagram (14/16)
Electrical Circuit Diagram (15/16)
Electrical Circuit Diagram (16/16)
Electrical Circuit Diagram of Inside of CAB (1/16)
Electrical Circuit Diagram of Inside of CAB (2/16)
Electrical Circuit Diagram of Inside of CAB (3/16)
Electrical Circuit Diagram of Inside of CAB (4/16)
Electrical Circuit Diagram of Inside of CAB (5/16)
Electrical Circuit Diagram of Inside of CAB (6/16)
Electrical Circuit Diagram of Inside of CAB (7/16)
Electrical Circuit Diagram of Inside of CAB (8/16)
Electrical Circuit Diagram of Inside of CAB (9/16)
Electrical Circuit Diagram of Inside of CAB (10/16)
Electrical Circuit Diagram of Inside of CAB (11/16)
Electrical Circuit Diagram of Inside of CAB (12/16)
Electrical Circuit Diagram of Inside of CAB (13/16)
Electrical Circuit Diagram of Inside of CAB (14/16)
Electrical Circuit Diagram of Inside of CAB (15/16)
Electrical Circuit Diagram of Inside of CAB (16/16)
Index