00Indexandforeword--------------------------------------------------------00-1
Foreword,safetyandgeneralinformation---------------------------------------00-13
Importantsafetynotice-------------------------------------------------00-13
Precautionstopreventfire-----------------------------------------------00-18
Howtoreadtheshopmanual--------------------------------------------00-20
Explanationoftermsformaintenancestandard--------------------------------00-22
Handlingequipmentoffuelsystemdevices-----------------------------------00-24
Handlingofintakesystemparts-------------------------------------------00-25
Handlingofhydraulicequipment------------------------------------------00-26
Methodofdisconnectingandconnectingofpush-pulltypecoupler------------------00-28
Handlingofelectricalequipment------------------------------------------00-31
Howtoreadelectricwirecode--------------------------------------------00-39
Precautionswhenperformingoperation-------------------------------------00-42
PracticaluseofKOMTRAX----------------------------------------------00-47
Standardtighteningtorquetable------------------------------------------00-48
Listofabbreviation----------------------------------------------------00-54
Conversiontable-----------------------------------------------------00-59
01Specification-------------------------------------------------------------01-1 Tableofcontents---------------------------------------------------------01-2 Specifications-----------------------------------------------------------01-3
Specificationdrawing--------------------------------------------------01-3 Specifications--------------------------------------------------------01-4
Weighttable---------------------------------------------------------01-9
Tableoffuel,coolant,andlubricants----------------------------------------01-11
10Structureandfunction------------------------------------------------------10-1
Tableofcontents---------------------------------------------------------10-2
Engineandcoolingsystem--------------------------------------------------10-3
Enginerelatedparts---------------------------------------------------10-3
Coolingsystem------------------------------------------------------10-5
Coolingfanmotor-----------------------------------------------------10-7
OilcoolerbypassandHSTchargesafetyvalve--------------------------------10-13
Powertrain-------------------------------------------------------------10-19
Powertrainsystem----------------------------------------------------10-19
Damper------------------------------------------------------------10-22
HydrauliccomponentlayoutofHST----------------------------------------10-23
Steeringandbrakecontrol-----------------------------------------------10-24
HSTpump----------------------------------------------------------10-26
HSTmotor----------------------------------------------------------10-41
Chargepump--------------------------------------------------------10-56
Solenoidvalve-------------------------------------------------------10-57
Finaldrive----------------------------------------------------------10-66
Undercarriageandframe---------------------------------------------------10-70
Mainframe---------------------------------------------------------10-70
Suspension---------------------------------------------------------10-71
Trackframeandidlercushion--------------------------------------------10-73
Hydraulicsystem---------------------------------------------------------10-75
Hydrauliccomponentlayoutofworkequipment--------------------------------10-75
Workequipmentcontrolsystem-------------------------------------------10-76
Hydraulictank-------------------------------------------------------10-77
CLSS-------------------------------------------------------------10-79
Workequipmentandcoolingfanpump--------------------------------------10-82
Controlvalve--------------------------------------------------------10-93
Accumulator--------------------------------------------------------10-119
Workequipment---------------------------------------------------------10-121
Planterunit---------------------------------------------------------10-121
Cabanditsattachments---------------------------------------------------10-122
ROPScab---------------------------------------------------------10-122
Cabmount---------------------------------------------------------10-124
Electricalsystem--------------------------------------------------------10-125
Enginecontrolsystem-------------------------------------------------10-125
Coolingsystemcontrolsystem-------------------------------------------10-128
HSTcontrolsystem---------------------------------------------------10-130
Parkingbrakecontrolsystem--------------------------------------------10-141
Systemoperatinglampfunction------------------------------------------10-144
Batterydisconnectswitchfunction----------------------------------------10-145
Machinemonitorsystem-----------------------------------------------10-147
KOMTRAXsystem---------------------------------------------------10-170
Systemcomponentparts-----------------------------------------------10-173
HSTcontroller------------------------------------------------------10-176
Sensor------------------------------------------------------------10-188
20Standardvaluetables-------------------------------------------------------20-1
Tableofcontents---------------------------------------------------------20-2
Standardservicevaluetable-------------------------------------------------20-3
Standardvaluetableforengine-------------------------------------------20-3
Standardvaluetableformachine------------------------------------------20-4
Standardvaluetableforelectricalsystem------------------------------------20-10
30Testingandadjusting------------------------------------------------------30-1
Tableofcontents--------------------------------------------------------30-2
Relatedinformationontestingandadjusting------------------------------------30-4
Toolsfortestingandadjusting-------------------------------------------30-4
Sketchoftoolsfortestingandadjusting------------------------------------30-7
Engineandcoolingsystem-------------------------------------------------30-9
Testingenginespeed-------------------------------------------------30-9
Testingboostpressure------------------------------------------------30-11
Testingexhaustgascolor----------------------------------------------30-13
Testingandadjustingvalveclearance--------------------------------------30-15
Measuringcompressionpressure-----------------------------------------30-18
Testingblowbypressure-----------------------------------------------30-21
Testingengineoilpressure---------------------------------------------30-22
Testingfuelpressure--------------------------------------------------30-23
Testingfueldischarge,returnandleakage-----------------------------------30-28
Bleedingairfromfuelsystem--------------------------------------------30-33
Testingfuelcircuitforleakage-------------------------------------------30-35
Handlingcylindercutoutmodeoperation------------------------------------30-36
Handlingno-injectioncrankingoperation------------------------------------30-37
Testingofinstalledconditionofcylinderheadsandmanifolds---------------------30-38
Testingenginepipingfordamageandlooseness------------------------------30-39
Checkalternatorbelt,replace--------------------------------------------30-40
Powertrain------------------------------------------------------------30-42
TestingandadjustingHSToilpressure-------------------------------------30-42
Testingoutputpressureofsolenoidvalve-----------------------------------30-47
Testingifmachinetravelsstraight-----------------------------------------30-51
Simpletestprocedureforbrakeperformance--------------------------------30-52
Adjustingdeceleration/brakepedal----------------------------------------30-53
Adjustingparkingbrakelever--------------------------------------------30-56
Movedisabledmachineurgently-----------------------------------------30-58
Undercarriageandframe--------------------------------------------------30-61
Adjustingidlerclearance-----------------------------------------------30-61
Checkingsprocketwear-----------------------------------------------30-62
Testingandadjustingtracktension----------------------------------------30-63
Hydraulicsystem--------------------------------------------------------30-64
Releasingremainingpressureinworkequipmentcylinder-----------------------30-64
Testingandadjustingworkequipmentoilpressure----------------------------30-65
Testingsourcepressureofcontrolcircuit-----------------------------------30-67
TestingoutletpressureofworkequipmentEPCvalveandfanEPCvalve------------30-68
Testinginternaloilleakageofworkequipmentcylinder-------------------------30-70
Testingfanspeed----------------------------------------------------30-71
Testingfancircuitoilpressure-------------------------------------------30-72
Bleedingairfromhydrauliccircuit-----------------------------------------30-73
Workequipment--------------------------------------------------------30-74
Adjustingworkequipmentlocklever---------------------------------------30-74
Electricalsystem--------------------------------------------------------30-76
Specialfunctionsofmachinemonitor--------------------------------------30-76
AdjustmentmethodwhenHSTcontrollerhasbeenreplaced---------------------30-146
Adjustmentmethodwhenelectricorhydraulicdevicehasbeenreplaced-------------30-149
Adjustingrearviewcameraangle-----------------------------------------30-150
Handlingvoltagecircuitofenginecontroller---------------------------------30-151
Handlingbatterydisconnectswitch---------------------------------------30-152
Testingdiodes------------------------------------------------------30-153
Pmclinic--------------------------------------------------------------30-154
PmClinicservice----------------------------------------------------30-154
PmClinicchecksheet-------------------------------------------------30-156
40Troubleshooting----------------------------------------------------------40-1
Tableofcontents--------------------------------------------------------40-2
Relatedinformationontroubleshooting----------------------------------------40-8
Troubleshootingpoints------------------------------------------------40-8
Sequenceofeventsintroubleshooting-------------------------------------40-10
Checksbeforetroubleshooting------------------------------------------40-12
Inspectionprocedurebeforetroubleshooting---------------------------------40-14
Preparationfortroubleshootingofelectricalsystem----------------------------40-31
Classificationandproceduresfortroubleshooting-----------------------------40-35
Symptomandtroubleshootingnumbers------------------------------------40-37
Informationintroubleshootingtable---------------------------------------40-39
Procedurefortroubleshootingwiringharnessofpressuresensorsystemforopencircuit-40-41
Connectorlistandlayout-----------------------------------------------40-44
Connectorcontactidentification------------------------------------------40-58
T-branchboxandT-branchadaptertable-----------------------------------40-97
Fuselocationtable---------------------------------------------------40-102
Failurecodestable---------------------------------------------------40-107
Troubleshootingbyfailurecode(Displayofcode)---------------------------------40-115
Failurecode[6091NX]HSTOilFilterClogging-------------------------------40-115
Failurecode[989L00]EngineControllerLockCaution1------------------------40-117
Failurecode[989M00]EngineControllerLockCaution2------------------------40-118
Failurecode[989N00]EngineControllerLockCaution3------------------------40-119
Failurecode[AA10NX]AirCleanerClogging--------------------------------40-120
Failurecode[AB00KE]ChargeVoltageLow---------------------------------40-122
Failurecode[B@BAZG]EngOilPressLow---------------------------------40-124
Failurecode[B@BCNS]EngWaterOverheat--------------------------------40-125
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Failurecode[B@CRNS]HSTOilOverheat----------------------------------40-126 Failurecode[B@CRZG]HSTChargePressLow------------------------------40-127 Failurecode[CA111]ECMCriticalInternalFailure-----------------------------40-128 Failurecode[CA115]EngNeandBkupSpeedSensError-----------------------40-129 Failurecode[CA122]ChgAirPressSensorHighError-------------------------40-130 Failurecode[CA123]ChgAirPressSensorLowError--------------------------40-132 Failurecode[CA131]ThrottleSensorHighError------------------------------40-134 Failurecode[CA132]ThrottleSensorLowError------------------------------40-136 Failurecode[CA144]CoolantTempSensHighError---------------------------40-138 Failurecode[CA145]CoolantTempSensLowError---------------------------40-140 Failurecode[CA153]ChgAirTempSensorHighError--------------------------40-142 Failurecode[CA154]ChgAirTempSensorLowError--------------------------40-144 Failurecode[CA187]Sensor2SupplyVoltLowError--------------------------40-146 Failurecode[CA221]AmbientPressSensorHighError-------------------------40-148 Failurecode[CA222]AmbientPressSensorLowError-------------------------40-150 Failurecode[CA227]Sensor2SupplyVoltHighError--------------------------40-152 Failurecode[CA234]EngOverspeed--------------------------------------40-153 Failurecode[CA238]NeSpeedSensorSupplyVoltError------------------------40-154 Failurecode[CA271]IMV/PCV1ShortError---------------------------------40-155 Failurecode[CA272]IMV/PCV1OpenError---------------------------------40-157
Failurecode[CA322]Inj#1(L#1)Open/ShortError----------------------------40-159
Failurecode[CA323]Inj#5(L#5)Open/ShortError----------------------------40-161 Failurecode[CA324]Inj#3(L#3)Open/ShortError----------------------------40-163
Failurecode[CA325]Inj#6(L#6)Open/ShortError----------------------------40-165 Failurecode[CA331]Inj#2(L#2)Open/ShortError----------------------------40-167
Failurecode[CA332]Inj#4(L#4)Open/ShortError----------------------------40-169 Failurecode[CA342]CalibrationCodeIncompatibility--------------------------40-171 Failurecode[CA351]InjectorsDriveCircuitError-----------------------------40-172 Failurecode[CA352]Sensor1SupplyVoltLowError--------------------------40-173 Failurecode[CA386]Sensor1SupplyVoltHighError--------------------------40-175 Failurecode[CA428]WaterinFuelSensorHighError--------------------------40-176 Failurecode[CA429]WaterinFuelSensorLowError--------------------------40-178 Failurecode[CA435]EngOilPressSwError--------------------------------40-180 Failurecode[CA441]BatteryVoltageLowError------------------------------40-181 Failurecode[CA442]BatteryVoltageHighError------------------------------40-183 Failurecode[CA449]RailPressVeryHighError------------------------------40-184 Failurecode[CA451]RailPressSensorHighError----------------------------40-185 Failurecode[CA452]RailPressSensorLowError----------------------------40-187 Failurecode[CA488]ChgAirTempHighTorqueDerate-------------------------40-189 Failurecode[CA553]RailPressHighError----------------------------------40-190 Failurecode[CA689]EngNeSpeedSensorError-----------------------------40-191 Failurecode[CA731]EngBkupSpeedSensPhaseError------------------------40-193
Failurecode[CA757]AllcontinuousDataLostError---------------------------40-195
Failurecode[CA778]EngBkupSpeedSensorError---------------------------40-196
Failurecode[CA2185]ThrotSensorSupVoltHighError------------------------40-201
Failurecode[CA2186]ThrotSensorSupVoltLowError-------------------------40-202
Failurecode[CA2249]RailPressVeryLowError-----------------------------40-203
Failurecode[CA2311]IMVSolenoidError----------------------------------40-204
Failurecode[CA2555]GridHtrRelayVoltLowError---------------------------40-205
Failurecode[CA2556]GridHtrRelayVoltHighError---------------------------40-207
Failurecode[D130KA]NeutralrelayOpen----------------------------------40-209
Failurecode[D130KB]NeutralrelayShortcircuit------------------------------40-211
Failurecode[D130KY]Neutralrelay:HotShort-------------------------------40-213
Failurecode[D19JKZ]PersonalCodeRelayAbnormality------------------------40-215
Failurecode[D811MC]KOMTRAXError-----------------------------------40-218 Failurecode[D862KA]GPSAntennaOpenCircuit----------------------------40-219 Failurecode[D8ALKA]OperatingLampOpenCircuit(KOMTRAX)-----------------40-220 Failurecode[D8ALKB]OperatingLampShortCircuit(KOMTRAX)-----------------40-222 Failurecode[D8AQKR]CAN2Discon(KOMTRAX)----------------------------40-223 Failurecode[DAF0MB]MonitorROMAbnormality----------------------------40-224 Failurecode[DAF0MC]MonitorError--------------------------------------40-225 Failurecode[DAF8KB]CameraPowerSupplyShortCircuit----------------------40-226 Failurecode[DAF9KQ]ModelSelectionAbnormality---------------------------40-227 Failurecode[DAFGMC]GPSModuleError---------------------------------40-228 Failurecode[DAFLKA]OperatingLampOpenCircuit(Monitor)-------------------40-229 Failurecode[DAFLKB]OperatingLampShortCircuit(Monitor)-------------------40-231 Failurecode[DAFQKR]CAN2Discon(Monitor)------------------------------40-232 Failurecode[DAJ000]HSTcontroller:Abnormalityincontroller-------------------40-233 Failurecode[DAJ0KQ]HSTcontroller:Typeselectsignal-----------------------40-234 Failurecode[DAJ0KT]HSTcontroller:Abnormalityincontroller-------------------40-235 Failurecode[DAJ0MC]HSTConError------------------------------------40-236 Failurecode[DAJ1KK]HSTcontroller:Sourcevoltagelow----------------------40-237 Failurecode[DAJ2KK]HSTcontroller:Outputvoltagelow-----------------------40-239 Failurecode[DAJ5KK]HST:Sensorvolt5V(0)Outofnormalrange----------------40-241
Failurecode[DAJ6KK]HST:Sensorvolt5V(1)Outofnormalrange----------------40-244 Failurecode[DAJLKA]OperatingLampOpenCircuit(HSTCon)------------------40-246 Failurecode[DAJLKB]OperatingLampShortCircuit(HSTCon)------------------40-248 Failurecode[DAJPMA]InconsistencyofOptionSelection(HST)------------------40-249 Failurecode[DAJQKR]CAN2Discon(HSTCon)-----------------------------40-250 Failurecode[DAJRKR]CAN1Discon(HSTCon)-----------------------------40-251 Failurecode[DB2QKR]CAN2Discon(EngineCon)---------------------------40-252 Failurecode[DD12KA]ShiftupSW:Open----------------------------------40-256 Failurecode[DD12KB]ShiftupSW:ShortCircuit-----------------------------40-258 Failurecode[DD13KA]ShiftdownSW:Open--------------------------------40-260 Failurecode[DD13KB]ShiftdownSW:ShortCircuit---------------------------40-262 Failurecode[DD14KA]ParkingleverSW:Open------------------------------40-264 Failurecode[DD14KB]ParkingleverSW:Shortcircuit-------------------------40-267 Failurecode[DDKAKA]BladefloatSw:Open--------------------------------40-271 Failurecode[DDKAKB]BladefloatSw:Shortcircuit---------------------------40-273 Failurecode[DDKFL4]LeftAngleSw:Signalmismatch-------------------------40-275 Failurecode[DDKGL4]RightAngleSw:Signalmismatch-----------------------40-277 Failurecode[DDKHKA]iBSw:Open--------------------------------------40-279 Failurecode[DDKHKB]iBSw:Shortcircuit---------------------------------40-281 Failurecode[DDNLKA]WeqlockSw:Open---------------------------------40-283 Failurecode[DDNLKB]WeqlockSw:Shortcircuit----------------------------40-286 Failurecode[DDP6KA]BrakePressureSensor:Open-------------------------40-289 Failurecode[DDP6KB]BrakePressureSensor:HotShort-----------------------40-291 Failurecode[DDP6MA]Brakepressuresensor:Malfunction---------------------40-293 Failurecode[DDU1FS]ParkingleverSwitch2:Signalmismatch------------------40-295 Failurecode[DDU1KA]ParkingleverSw2:Open-----------------------------40-298 Failurecode[DDU1KY]ParkingleverSw2:HotShort--------------------------40-301 Failurecode[DFA4KX]Bladeliftlever:MainandSubError----------------------40-303 Failurecode[DFA4KZ]Bladeliftlever:MainandSubError----------------------40-304 Failurecode[DFA4L8]Bladeliftlever:Signalmismatch-------------------------40-305 Failurecode[DFA5KA]Bladeliftlever1:Open-------------------------------40-306 Failurecode[DFA5KB]Bladeliftlever1:HotShort-----------------------------40-309 Failurecode[DFA6KA]Bladeliftlever2:Open-------------------------------40-311 Failurecode[DFA6KB]Bladeliftlever2:HotShort-----------------------------40-313
Failurecode[DFA7KX]Bladetiltlever:MainandSubError----------------------40-315 Failurecode[DFA7KZ]Bladetiltlever:MainandSubError-----------------------40-316
Failurecode[DFA7L8]Bladetiltlever:Signalmismatch-------------------------40-317 Failurecode[DFA8KA]Bladetiltlever1:Open--------------------------------40-318 Failurecode[DFA8KB]Bladetiltlever1:HotShort-----------------------------40-321 Failurecode[DFA9KA]Bladetiltlever2:Open--------------------------------40-323
Failurecode[DFA9KB]Bladetiltlever2:HotShort-----------------------------40-326 Failurecode[DGS1KA]HSToiltempsensor:Open----------------------------40-328 Failurecode[DGS1KX]HSToiltempsensor:Outofnormalrange-----------------40-330 Failurecode[DH21KA]Weqpressuresensor:Open---------------------------40-331 Failurecode[DH21KB]Weqpressuresensor:HotShort------------------------40-333
Failurecode[DHA4KA]AirCleanerClogSensorOpenCircuit--------------------40-335 Failurecode[DHH7KA]LFHSTPressureSensor:Open------------------------40-337 Failurecode[DHH7KB]LFHSTPressureSensor:HotShort---------------------40-339 Failurecode[DHH8KA]RFHSTPressureSensor:Open------------------------40-341 Failurecode[DHH8KB]RFHSTPressureSensor:HotShort---------------------40-343 Failurecode[DHH9KA]LRHSTPressureSensor:Open------------------------40-345 Failurecode[DHH9KB]LRHSTPressureSensor:HotShort---------------------40-347 Failurecode[DHHAKA]RRHSTPressureSensor:Open------------------------40-349 Failurecode[DHHAKB]RRHSTPressureSensor:HotShort---------------------40-351 Failurecode[DK30KA]STlever1:Open------------------------------------40-353 Failurecode[DK30KB]STlever1:HotShort---------------------------------40-356 Failurecode[DK30KX]STlever:MainandSubError---------------------------40-358 Failurecode[DK30KZ]STlever:MainandSubError---------------------------40-359 Failurecode[DK30L8]STlever:Signalmismatch-----------------------------40-360 Failurecode[DK31KA]STlever2:Open------------------------------------40-361 Failurecode[DK31KB]STlever2:HotShort---------------------------------40-364 Failurecode[DK40KA]Decel/Brakepotentiometer:Open------------------------40-366 Failurecode[DK40KB]Decel/Brakepotentiometer:HotShort---------------------40-369 Failurecode[DK55KX]FRlever:MainandSubError---------------------------40-371 Failurecode[DK55KZ]FRlever:MainandSubError---------------------------40-372 Failurecode[DK55L8]FRlever:Signalmismatch-----------------------------40-373 Failurecode[DK56KA]FRlever1:Open------------------------------------40-374 Failurecode[DK56KB]FRlever1:HotShort---------------------------------40-377 Failurecode[DK57KA]FRlever2:Open------------------------------------40-380 Failurecode[DK57KB]FRlever2:HotShort---------------------------------40-383 Failurecode[DLM0KX]HSTMotorSpeedSensor:Left/RightError-----------------40-385 Failurecode[DLM1KA]LeftHSTmotorspeedsensor:Open---------------------40-386 Failurecode[DLM1KB]LeftHSTmotorspeedsensor:Shortcircuit-----------------40-388 Failurecode[DLM1MA]LeftHSTmotorspeedsensor:Malfunction-----------------40-390 Failurecode[DLM2KA]RightHSTmotorspeedsensor:Open--------------------40-391 Failurecode[DLM2KB]RightHSTmotorspeedsensor:Shortcircuit----------------40-393
Failurecode[DLM2MA]RightHSTmotorspeedsensor:Malfunction----------------40-395
Failurecode[DLM3KA]Fanrev.sensor:Open-------------------------------40-396
Failurecode[DLM3KB]Fanrev.sensor:Shortcircuit---------------------------40-398
Failurecode[DLM3MB]Fancontrol:Mismatch-------------------------------40-400
Failurecode[DN21FS]Decel/BrakepedalSW:Signalmismatch------------------40-401 Failurecode[DR21KX]Camera2PictureRev.DriveAbnormality------------------40-403 Failurecode[DR31KX]Camera3PictureRev.DriveAbnormality------------------40-404
Failurecode[DV20KB]Back-upalarm:Shortcircuit----------------------------40-405
Failurecode[DW4BKA]Parkingbrakesolenoid:Open--------------------------40-407
Failurecode[DW4BKB]Parkingbrakesolenoid:Shortcircuit---------------------40-409
Failurecode[DW4BKY]Parkingbrakesolenoid:HotShort-----------------------40-411 Failurecode[DW7BKA]Fanreversesolenoid:Open---------------------------40-413
Failurecode[DW7BKB]Fanreversesolenoid:Shortcircuit----------------------40-415 Failurecode[DW7EKA]Slowbrakesolenoid:Open---------------------------40-416 Failurecode[DW7EKB]Slowbrakesolenoid:Shortcircuit-----------------------40-418 Failurecode[DW7EKY]Slowbrakesolenoid:HotShort------------------------40-420 Failurecode[DWN5KA]FanEPC:Open-----------------------------------40-422 Failurecode[DWN5KB]FanEPC:Shortcircuit-------------------------------40-424 Failurecode[DWN5KY]FanEPC:HotShort--------------------------------40-425 Failurecode[DXA4KA]LFHSTpumpEPC:Open----------------------------40-427 Failurecode[DXA4KB]LFHSTpumpEPC:Shortcircuit------------------------40-429 Failurecode[DXA4KY]LFHSTpumpEPC:HotShort--------------------------40-430 Failurecode[DXA5KA]LRHSTpumpEPC:Open----------------------------40-432 Failurecode[DXA5KB]LRHSTpumpEPC:Shortcircuit------------------------40-434 Failurecode[DXA5KY]LRHSTpumpEPC:HotShort-------------------------40-436 Failurecode[DXA6KA]RFHSTpumpEPC:Open----------------------------40-438 Failurecode[DXA6KB]RFHSTpumpEPC:Shortcircuit------------------------40-440 Failurecode[DXA6KY]RFHSTpumpEPC:HotShort-------------------------40-441 Failurecode[DXA7KA]RRHSTpumpEPC:Open----------------------------40-443 Failurecode[DXA7KB]RRHSTpumpEPC:Shortcircuit-----------------------40-445 Failurecode[DXA7KY]RRHSTpumpEPC:HotShort-------------------------40-446 Failurecode[DXHRKA]BladeliftupEPC:Open------------------------------40-448 Failurecode[DXHRKB]BladeliftupEPC:Shortcircuit-------------------------40-451 Failurecode[DXHRKY]BladeliftupEPC:Hotshort---------------------------40-453 Failurecode[DXHSKA]BladeliftdownEPC:Open----------------------------40-455 Failurecode[DXHSKB]BladeliftdownEPC:Shortcircuit-----------------------40-458 Failurecode[DXHSKY]BladeliftdownEPC:Hotshort-------------------------40-460 Failurecode[DXHTKA]BladetiltleftEPC:Open------------------------------40-462 Failurecode[DXHTKB]BladetiltleftEPC:Shortcircuit-------------------------40-464 Failurecode[DXHTKY]BladetiltleftEPC:Hotshort---------------------------40-465 Failurecode[DXHUKA]BladetiltrightEPC:Open----------------------------40-467 Failurecode[DXHUKB]BladetiltrightEPC:Shortcircuit------------------------40-469 Failurecode[DXHUKY]BladetiltrightEPC:Hotshort--------------------------40-470 Failurecode[DXJ4KA]WeqlockSol.:Open---------------------------------40-472 Failurecode[DXJ4KB]WeqlockSol.:Shortcircuit----------------------------40-474 Failurecode[DXJCKA]BladeangleleftEPC:Open---------------------------40-476 Failurecode[DXJCKB]BladeangleleftEPC:Shortcircuit-----------------------40-477 Failurecode[DXJCKY]BladeangleleftEPC:Hotshort-------------------------40-478 Failurecode[DXJDKA]BladeanglerightEPC:Open--------------------------40-480 Failurecode[DXJDKB]BladeanglerightEPC:Shortcircuit----------------------40-481 Failurecode[DXJDKY]BladeanglerightEPC:Hotshort------------------------40-482
Failurecode[DXK1KA]LeftHSTmotorEPC:Open----------------------------40-484
Failurecode[DXK1KB]LeftHSTmotorEPC:Shortcircuit-----------------------40-486
Failurecode[DXK1KY]LeftHSTmotorEPC:HotShort-------------------------40-487
Failurecode[DXK2KA]RightHSTmotorEPC:Open--------------------------40-489
Failurecode[DXK2KB]RightHSTmotorEPC:Shortcircuit----------------------40-491
Failurecode[DXK2KY]RightHSTmotorEPC:HotShort------------------------40-492
Troubleshootingofelectricalsystem(E-mode)-----------------------------------40-494
E-1Enginedoesnotstart(Enginedoesnotcrank)----------------------------40-494
E-2Manualpreheatingsystemdoesnotwork--------------------------------40-500
E-3Automaticpreheatingsystemdoesnotwork------------------------------40-503
E-4Whilepreheatingisworking,preheatingmonitordoesnotlightup---------------40-505
E-5WhenstartingswitchisturnedtoONposition,machinemonitordisplaysnothing----40-507
E-6WhenstartingswitchisturnedtoONposition(withenginestopped),basiccheckmonitorlights up--------------------------------------------------------40-510
E-7Aircleanercloggingmonitorlightsupinyellowwhileengineisrunning-----------40-511
E-8Chargelevelmonitorlightsupinredwhileengineisrunning-------------------40-512
E-9Enginecoolanttemperaturemonitorlightsupinredwhileengineisrunning--------40-513
E-10Engineoilpressuremonitorlightsupinredwhileengineisrunning-------------40-514
E-11HSTchargepressuremonitorlightsupinredwhileengineisrunning------------40-515
E-12Hydraulicoiltemperaturemonitorlightsupinredwhileengineisrunning---------40-516
E-13HSToilfiltercloggingmonitorlightsupinredwhileengineisrunning-----------40-517
E-14Fuellevelgaugedoesnotindicatecorrectlevel---------------------------40-518
E-15Enginecoolanttemperaturegaugedoesnotindicatecorrecttemperature--------40-521
E-16Hydraulicoiltemperaturegaugedoesnotindicatecorrecttemperature----------40-522
E-17Operationmodedoesnotchange-------------------------------------40-523
E-18Servicemodecannotbeselected-------------------------------------40-524
E-19Operatingcustomizeswitchdoesnotdisplaycustomizescreen----------------40-525
E-20Modifyingsettingoncustomizescreendoesnotchangesettingofmachine-------40-526
E-21Servicemeterisnotdisplayed,whilestartingswitchisinOFFposition-----------40-527
E-22Workequipmentdoesnotoperate------------------------------------40-528
E-23Footheaterdoesnotoperate----------------------------------------40-530
E-24Horndoesnotsound----------------------------------------------40-535
E-25Horndoesnotstopsounding----------------------------------------40-537
E-26Backupalarmdoesnotsound---------------------------------------40-538
E-27Backupalarmdoesnotstopsounding----------------------------------40-539
E-28Headlampdoesnotlightup-----------------------------------------40-540
E-29Rearlampdoesnotlightup-----------------------------------------40-543
E-30Nowiperoperatescontinuouslyorintermittently---------------------------40-546
E-31Frontwiperdoesnotoperate----------------------------------------40-548
E-32Rearwiperdoesnotoperate----------------------------------------40-550
E-33Leftdoorwiperdoesnotoperate(failedinbothcontinuousandintermittentoperations)40-552
E-34Rightdoorwiperdoesnotoperate(failedinbothcontinuousandintermittentoperations)-40-556
E-35Frontwasherdoesnotoperate---------------------------------------40-560
E-36Rearwasherdoesnotoperate---------------------------------------40-562
E-37Leftdoorwasherdoesnotoperate------------------------------------40-564
E-38Rightdoorwasherdoesnotoperate-----------------------------------40-566
E-39KOMTRAXsystemdoesnotoperatenormally----------------------------40-568
Troubleshootingofhydraulicandmechanicalsystem(H-mode)-----------------------40-570
Informationdescribedintroubleshootingtable(H-mode)------------------------40-570
Failuremodeandcausetable-------------------------------------------40-571
H-1NeitherRHnorLHoftracksdoesnottravelforwardnorreverse(Noneofthetravelsystem operates)---------------------------------------------------40-574
H-2EitherRHorLHoftrackdoesnottravelforwardnorreverse(OnlyRHorLHoftravelsystem operates)---------------------------------------------------40-576
H-3EitherRHorLHoftracktravelonlyforwardorreverse(OnlyforwardorreverseofRHorLHof travelsystemdoesnotoperate)-----------------------------------40-577
H-4Travelspeedorpowerislow-----------------------------------------40-579
H-5Shockislargewhenmachinestartsorstops------------------------------40-580
H-6Machinedeviateslargely--------------------------------------------40-581
H-7Machinedriftonaslopeislarge---------------------------------------40-583
H-8Enginestallsduringtravelorenginespeeddropssignificantly-----------------40-584
H-9UnusualnoiseisheardfromaroundHSTpumpormotor---------------------40-586
H-10Allworkequipmentdonotoperate------------------------------------40-587
H-11Allworkequipmentoperatesslowlyorlackspower------------------------40-589
H-12Frontworkequipmentliftspeedorpowerislow---------------------------40-590
H-13Frontworkequipmentsideswingspeedorpowerislow---------------------40-591
H-14Hydraulicdriftofliftedfrontworkequipmentislarge------------------------40-592
H-15Unusualnoiseisheardfromaroundworkequipmentpumporcontrolvalve-------40-593
H-16HSToiltemperature(hydraulicoiltemperature)risestoohigh-----------------40-594
H-17Fanspeedisabnormal(high,low,ornorotation)--------------------------40-596
H-18Unusualnoiseisheardfromaroundfan--------------------------------40-598
Troubleshootingofengine(S-mode)------------------------------------------40-599
Methodofusingtroubleshootingcharts------------------------------------40-599
S-1Startingperformanceispoor-----------------------------------------40-603
S-2Enginedoesnotstart----------------------------------------------40-604
S-3Enginedoesnotpickupsmoothly-------------------------------------40-607
S-4Enginestopsduringoperations---------------------------------------40-608
S-5Enginedoesnotrotatesmoothly--------------------------------------40-609
S-6Enginelacksoutput(orlackspower)-----------------------------------40-610
S-7Exhaustsmokeisblack(incompletecombustion)--------------------------40-611
S-8Oilconsumptionisexcessive(orexhaustsmokeisblue)---------------------40-612
S-9Oilbecomescontaminatedquickly-------------------------------------40-613
S-10Fuelconsumptionisexcessive---------------------------------------40-614
S-11Oilisincoolant(orcoolantspurtsbackorcoolantlevelgoesdown)------------40-615
S-12Oilpressuredrops-----------------------------------------------40-616
S-13Oillevelrises(Entryofcoolantorfuel)---------------------------------40-617
S-14Coolanttemperaturebecomestoohigh(overheating)----------------------40-618
S-15Abnormalnoiseismade-------------------------------------------40-619
S-16Vibrationisexcessive---------------------------------------------40-620
50Disassemblyandassembly---------------------------------------------------50-1
Tableofcontents---------------------------------------------------------50-2
Relatedinformationondisassemblyandassembly---------------------------------50-4
Howtoreadthismanual------------------------------------------------50-4
Coatingmaterialslist--------------------------------------------------50-6
Specialtoolslist------------------------------------------------------50-10
Sketchesofspecialtools------------------------------------------------50-16
Engineandcoolingsystem--------------------------------------------------50-29
Removalandinstallationofsupplypumpassembly-----------------------------50-29
Removalandinstallationoffuelinjectorassembly------------------------------50-33
Removalandinstallationofcylinderheadassembly----------------------------50-40
Removalandinstallationofradiatorassembly---------------------------------50-54
Removalandinstallationofaftercoolerassembly------------------------------50-58
Removalandinstallationofhydraulicoilcoolerassembly-------------------------50-61
Removalandinstallationofcoolingfandriveassembly--------------------------50-64
Removalandinstallationofcoolingfanmotorassembly--------------------------50-67
Removalandinstallationofengineassembly---------------------------------50-69
Disassemblyandassemblyofdamperassembly-------------------------------50-76
Removalandinstallationofenginefrontoilseal-------------------------------50-77
Removalandinstallationofenginerearoilseal--------------------------------50-79
Removalandinstallationofenginehoodassembly-----------------------------50-82
Removalandinstallationoffueltankassembly--------------------------------50-85
Removalandinstallationofmuffler-----------------------------------------50-90
Removalandinstallationofbeltforalternatorandairconditionercompressor----------50-92
Removalandinstallationofaircleanerassembly-------------------------------50-93
Powertrain-------------------------------------------------------------50-95
RemovalandinstallationofHSTpumpassembly------------------------------50-95
RemovalandinstallationofHSTmotorandfinaldriveassembly--------------------50-97
Disassemblyandassemblyoffinaldrive------------------------------------50-100
Undercarriageandframe--------------------------------------------------50-110
Removalandinstallationoftrackframeassembly-----------------------------50-110
Removalandinstallationofidlerassembly----------------------------------50-114
Disassemblyandassemblyofidler---------------------------------------50-116
Removalandinstallationofrecoilspringassembly----------------------------50-120
Disassemblyandassemblyofrecoilspring----------------------------------50-121
Removalandinstallationoftrackrollerassembly------------------------------50-125
Disassemblyandassemblyoftrackrollerassembly----------------------------50-127
Removalandinstallationofcarrierrollerassembly-----------------------------50-130
Disassemblyandassemblyofcarrierrollerassembly---------------------------50-132
Removalandinstallationofsegmentteeth----------------------------------50-134
Separationandconnectionoftrackshoeassembly(Standardtypetrackshoe)---------50-135
Overalldisassemblyandassemblyoftrackshoeassembly(Standardtypetrackshoe)---50-138
Disassemblyandassemblyofonetracklinkassemblyinfield(Standardtypetrackshoe)-50-154
Removalandinstallationofpivotshaftassembly------------------------------50-160
Removalandinstallationofequalizerbarassembly----------------------------50-162
Removalandinstallationofequalizerbarsidebushing--------------------------50-164
Hydraulicsystem--------------------------------------------------------50-165
Removalandinstallationofhydraulictankassembly---------------------------50-165
Removalandinstallationofcontrolvalveassembly----------------------------50-169
Disassemblyandassemblyofhydrauliccylinderassembly-----------------------50-172
Workequipment---------------------------------------------------------50-175
Removalandinstallationofplanterunitassembly-----------------------------50-175
Removalandinstallationofcenterframeassembly----------------------------50-177
Cabanditsattachments---------------------------------------------------50-179
RemovalandinstallationofROPScabassembly------------------------------50-179
Removalandinstallationofoperator'scabglass(adhesionglass)------------------50-183
Removalandinstallationofoperator'sseat----------------------------------50-189
Removalandinstallationofseatbelt---------------------------------------50-190
Removalandinstallationoffootheaterassembly------------------------------50-191
Disassemblyandassemblyoffootheaterassembly----------------------------50-193
Removalandinstallationofairconditionerunitassembly------------------------50-194
Removalandinstallationofairconditionercompressorassembly------------------50-198
Electricalsystem--------------------------------------------------------50-200
Removalandinstallationofmachinemonitorassembly-------------------------50-200
Removalandinstallationofenginecontrollerassembly-------------------------50-201
RemovalandinstallationofHSTcontrollerassembly---------------------------50-203
RemovalandinstallationofKOMTRAXterminal------------------------------50-204
60Maintenancestandard------------------------------------------------------60-1
Tableofcontents---------------------------------------------------------60-2
Engineandcoolingsystem--------------------------------------------------60-3
Enginemount--------------------------------------------------------60-3
Coolingfanmotor-----------------------------------------------------60-4
OilcoolerbypassandHSTchargesafetyvalve--------------------------------60-6
Powertrain-------------------------------------------------------------60-7
Damper------------------------------------------------------------60-7
HSTpump----------------------------------------------------------60-8
HSTmotor----------------------------------------------------------60-10
Chargepump--------------------------------------------------------60-11
Solenoidvalve-------------------------------------------------------60-12
Finaldrive----------------------------------------------------------60-13
Sprocket------------------------------------------------------------60-14
Full-scaledrawingofsprockettoothprofile-----------------------------------60-15
Undercarriageandframe---------------------------------------------------60-16
Suspension---------------------------------------------------------60-16
Trackframeandidlercushion--------------------------------------------60-18
Idler---------------------------------------------------------------60-20
Trackroller----------------------------------------------------------60-22
Carrierroller---------------------------------------------------------60-24
Trackshoe----------------------------------------------------------60-25
Hydraulicsystem---------------------------------------------------------60-28
Hydraulictank-------------------------------------------------------60-28
Workequipmentandcoolingfanpump--------------------------------------60-29
Controlvalve--------------------------------------------------------60-32
Anti-dropvalve-------------------------------------------------------60-39
Workequipment---------------------------------------------------------60-41
Planterunit---------------------------------------------------------60-41
Liftcylinder---------------------------------------------------------60-44
Swingcylinder-------------------------------------------------------60-45
Cabanditsattachments----------------------------------------------------60-46
Cabmount----------------------------------------------------------60-46
Electricalsystem---------------------------------------------------------60-47
Electricsteeringlever--------------------------------------------------60-47
80Appendix----------------------------------------------------------------80-1
Tableofcontents---------------------------------------------------------80-2
Airconditionercomponents-------------------------------------------------80-3
Precautionsforrefrigerant-----------------------------------------------80-3
Airconditionercomponent-----------------------------------------------80-4
Configurationandfunctionofrefrigerationcycle-------------------------------80-7
Outlineofrefrigerationcycle---------------------------------------------80-8
Airconditionerunit----------------------------------------------------80-10
Dualpressureswitch--------------------------------------------------80-14
Pressureswitch------------------------------------------------------80-15
Compressor---------------------------------------------------------80-16
Condenser----------------------------------------------------------80-17
Receiverdrier-------------------------------------------------------80-19
Procedurefortestingandtroubleshooting------------------------------------80-20
Electricalcircuitdiagram------------------------------------------------80-23
Systemdiagram------------------------------------------------------80-24
Partsandconnectorslayout---------------------------------------------80-26
Testingrelays--------------------------------------------------------80-31
Troubleshootingchart1-------------------------------------------------80-33
Troubleshootingchart2-------------------------------------------------80-34
Informationdescribedintroubleshootingtable---------------------------------80-36
A-1Troubleshootingforcondenserfan--------------------------------------80-37
A-2Troubleshootingforcompressorandrefrigerantsystem(Airisnotcooled)----------80-40
A-3Troubleshootingforblowermotorsystem(Noaircomesoutorairflowisabnormal)---80-44
A-4Troubleshootingfortemperaturecontrol----------------------------------80-46
Troubleshootingwithgaugepressure---------------------------------------80-49
Connectionofservicetool-----------------------------------------------80-52
Precautionsfordisconnectingandconnectinghosesandtubesinairconditionercircuit---80-54
Handlingofcompressoroil----------------------------------------------80-56
90Diagramsanddrawings-----------------------------------------------------90-1
Tableofcontents---------------------------------------------------------90-2
Hydrauliccircuitdiagram---------------------------------------------------90-3
Symbolsinhydrauliccircuitdiagram----------------------------------------90-3
Hydrauliccircuitdiagram------------------------------------------------90-7
Electriccircuitdiagram-----------------------------------------------------90-9
Symbolsinelectriccircuitdiagram-----------------------------------------90-9
Electriccircuitdiagram-------------------------------------------------90-13
00Indexandforeword
Foreword,safetyandgeneralinformation
00Indexandforeword
Foreword,safetyandgeneralinformation
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