Komatsu Bulldozer D65EX-18,D65PX-18,D65WX-18 Shop Manual SEN06715-09 PDF

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Komatsu Bulldozer D65EX-18,D65PX-18,D65WX-18 Shop Manual SEN06715-09 – PDF DOWNLOAD

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Komatsu Bulldozer D65EX-18,D65PX-18,D65WX-18 Shop Manual SEN06715-09 – PDF DOWNLOAD

Language : English
Pages : 3136
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer D65EX-18,D65PX-18,D65WX-18 Shop Manual SEN06715-09 – PDF DOWNLOAD

• SERIAL NUMBERS
  D65EX- 91310      and up
  D65PX- 91310      and up
  D65WX-91310      and up

Cover 1
00 Index and Foreword . 3
Index . 4
Abbreviation List . 22
Foreword, Safety, Basic Information . 28
How to Read the Shop Manual . 28
Safety Notice for Operation . 30
Precautions to Prevent Fire . 38
Procedures If Fire Occurs . 40
Precautions When You Discard Waste Materials 41
Procedures for Exhaust Gas Regulations 42
Precautions for DEF . 43
General Character and Precautions for Handling 43
Precautions When You Add 43
Precautions for Storage . 43
Precautions for Fire Hazard and Leakage . 43
Other Precautions . 43
Store DEF . 44
Precautions When You Handle Hydraulic Equipment . 45
Precautions When You Disconnect and Connect Pipings . 48
Precautions When You Handle Electrical Equipment 55
Precautions When You Handle Fuel System Equipment . 57
Precautions When You Handle Intake System Equipment . 58
Practical Use of KOMTRAX 59
Disconnect and Connect Push-Pull Type Coupler . 60
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 60
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 61
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 62
Precautions for Disconnection and Connection of Connectors 64
Disconnect and Connect Deutsch Connector 68
How to Disconnect and Connect Slide Lock Type Connector . 69
Disconnect and Connect Connector with Lock to Pull 71
Disconnect and Connect Connector with Lock to Push 72
Disconnect and Connect Connector with Housing to Rotate . 74
How to Read the Codes for Electric Cable 75
Explanation of Terms for Maintenance Standard . 79
Standard Tightening Torque Table 82
Conversion Table 89
01 Specification 95
Table of Contents . 96
Abbreviation List . 97
Specifications 103
Specification Drawing . 103
Specification Drawing: D65EX-18 . 103
Specification Drawing: D65PX-18 . 105
Specification Drawing: D65PX-18 (Wide Gauge Specification) 107
Specification Drawing: D65WX-18 . 109
Specifications 111
Specifications: D65EX-18 111
Specifications: D65PX-18 120
Specifications: D65PX-18 (Wide Gauge Specification) . 127
Specifications: D65WX-18 132
Weight Table 140
Weight Table: D65EX-18 140
Weight Table: D65PX-18 144
Weight Table: D65PX-18 (Wide Gauge Specification) . 147
Weight Table: D65WX-18 149
Table of Fuel, Coolant, and Lubricants 152
10 Structure and Function . 155
Table of Contents . 156
Abbreviation List . 159
Urea SCR System . 165
Layout Drawing of Urea SCR System . 165
Urea SCR System Diagram . 167
Function of Urea SCR System . 168
Function of DEF System 168
Inducement Strategy . 171
Component Parts of Urea SCR System 185
DEF Mixing Tube . 185
SCR Assembly 186
DEF Tank 188
DEF Pump 190
DEF Injector 191
DEF Hose 192
DEF Tank Heating Valve 193
Boot-up System 194
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 194
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) . 196
System Operating Lamp System 198
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 198
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) . 198
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 198
Function of System Operating Lamp System (Machine with Gateway Function Controller) . 199
Battery Disconnect Switch . 201
Layout Drawing of Battery Disconnect Switch . 201
Function of Battery Disconnect Switch . 201
Engine System . 203
Layout Drawing of Engine System . 203
Engine Control System . 205
Layout of Engine Control System (Machine with KOMTRAX Terminal) . 205
Layout of Engine Control System (Machine with Gateway Function Controller) 207
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) . 208
System Diagram of Engine Control System (Machine with Gateway Function Controller) 210
Function of Engine Control System (Machine with KOMTRAX Terminal) . 212
Function of Engine Control System (Machine with Gateway Function Controller) 214
Automatic Idle Stop System 216
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 216
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) . 217
Function of Automatic Idle Stop System 217
Component Parts of Engine System 220
Damper 220
VGT . 222
EGR System 226
EGR Valve . 228
EGR Cooler 230
KCCV System . 232
KCCV Ventilator . 234
KDPF 236
Cooling System 240
Layout Drawing of Cooling System 240
Specifications of Cooling System 241
Cooling Fan Control System 242
System Diagram of Cooling Fan Control System 242
Function of Cooling Fan Control System 243
Component Parts of Cooling System . 245
Cooling Fan Pump 245
Cooling Fan Motor . 254
Hydraulic Oil Cooler Bypass Valve . 261
Control System 262
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 262
Layout Drawing of Control System (Machine with Gateway Function Controller) . 263
Machine Monitor System 264
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 264
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) . 265
Function of Machine Monitor System 265
KOMTRAX System 266
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 266
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) . 266
Function of KOMTRAX System 267
Component Parts of Control System . 268
Machine Monitor . 268
KOMTRAX Terminal 284
Gateway Function Controller . 286
Communication Terminal 289
Power Train Controller 291
Engine Controller . 295
Hydraulic System 302
Layout Drawing of Hydraulic System 302
CLSS 303
Structure of CLSS . 303
Function of CLSS 304
Component Parts of Hydraulic System . 306
Hydraulic Tank 306
Work Equipment and HSS Pump . 308
LS Valve 314
PC Valve 319
PC-EPC Valve 324
Control Valve . 327
Power Train System 358
Layout Drawing of Power Train System 358
Operation of Power Train System . 361
Transmission, Steering, and Brake Control . 362
Layout Drawing of Transmission, Steering, and Brake Control System 362
Function of Transmission, Steering, and Brake Control . 363
Palm Command Control System . 364
Palm Command Control System Diagram . 364
HSS System 368
HSS System Diagram 368
Function of HSS System 369
Centralized Pressure Pickup Port 371
Layout Drawing of Centralized Pressure Pickup Port 371
Function of Centralized Pressure Pickup Port 371
Component Parts of Power Train System . 372
Universal Joint . 372
Power Train Mount . 373
Torque Converter and PTO 374
Lockup Clutch ECMV 380
Transmission 383
Transmission Control Valve 395
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 397
Main Relief Valve and Torque Converter Relief Valve . 402
Transmission Lubrication Relief Valve . 404
Bevel Gear Shaft, HSS, and Brake 405
Brake Valve . 424
Final Drive . 428
Scavenging Pump . 432
Steering Lubrication Pump and Power Train Pump 433
HSS Motor . 434
Electric Steering Electric Lever 440
Work Equipment System . 443
Work Equipment Control 443
Layout Drawing of Work Equipment Control 443
Function of Work Equipment Control 444
Layout Drawing of Tilt Dozer, Power Tilt Pitch Dozer, Angle Dozer and Semi-U Dozer Series . 446
Layout of Power Angle Power Tilt Dozer Series . 448
Layout Drawing of Fixed Multi-Shank Ripper 449
Component Parts of Work Equipment System 450
Self-Pressure Reducing Valve 450
Work Equipment Lock Solenoid Valve 456
Blade PPC Valve . 461
Ripper PPC Valve 467
Blade Pitch Selector Solenoid Valve . 470
Pilot Circuit Accumulator . 471
Angle Control EPC Valve . 472
Quick Drop Valve 475
Piston Valve 477
Undercarriage and Frame . 479
Main Frame 479
Structure of Main Frame . 479
Suspension 481
Structure of Suspension . 481
Specifications of Suspension 482
Function of Suspension 483
Track Frame and Idler Cushion . 484
Structure of Track Frame and Idler Cushion 484
Function of Track Frame and Idler Cushion . 486
Work Equipment 487
Structure of Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series) 487
Structure of Front Work Equipment (For Power Angle Power Tilt Dozer Series) . 488
Structure of Front Work Equipment (Angle Dozer Series) 489
Structure of Fixed Multi-Shank Ripper . 490
CAB Related Parts . 491
ROPS CAB 491
Structure of ROPS CAB (Machine with KOMTRAX Terminal) . 491
Structure of ROPS CAB (Machine with Gateway Function Controller) 492
Function of ROPS CAB 493
CAB Mount . 494
Structure of CAB Mount 494
Function of CAB Mount . 494
20 Standard Value Table . 495
Table of Contents . 496
Abbreviation List . 497
Standard Value Table for Engine . 503
Standard Value Table for Engine: D65EX-18 . 503
Standard Value Table for Engine: D65PX-18 . 508
Standard Value Table for Engine: D65WX-18 . 513
Standard Value Table for Machine 518
Standard Value Table for Machine: D65EX-18 518
Standard Value Table for Machine: D65PX-18 533
Standard Value Table for Machine: D65WX-18 548
Machine Posture and Procedures to Measure Performance . 563
Standard Value Table for Electricity 565
Standard Value Table for Electricity 565
30 Testing and Adjusting 575
Table of Contents . 576
Precautions Before Work . 579
Abbreviation List . 580
Related Information on Testing and Adjusting 586
Tools for Testing and Adjusting . 586
Sketch of Tools for Testing and Adjusting . 592
Engine and Cooling System . 593
Examine Engine Speed 593
How to Examine Engine Speed . 593
Examine Boost Pressure 597
How to Examine Boost Pressure . 597
Examine Exhaust Gas Temperature . 599
How to Examine Exhaust Gas Temperature 599
Examine Exhaust Gas Color . 601
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 601
How to Examine Exhaust Gas Color with Smoke Meter . 601
Examine Mass Air Flow and Temperature Sensor 603
How to Examine Mass Air Flow and Temperature Sensor . 603
Examine and Adjust Valve Clearance 605
Check Valve Clearance . 605
Adjust Valve Clearance 606
Examine Compression Pressure 608
How to Examine Compression Pressure . 608
Examine Blowby Pressure . 610
How to Examine Blowby Pressure 610
Examine Engine Oil Pressure . 613
How to Examine Engine Oil Pressure 613
Examine EGR Valve and VGT Oil Pressure 614
How to Examine EGR Valve and VGT Oil Pressure . 614
Examine Fuel Pressure . 616
How to Examine Fuel Pressure 617
Examine Fuel Discharge, Return and Leakage 623
How to Examine Fuel Discharge, Return, and Leakage 624
Bleed Air from Fuel System 628
How to Bleed Air from Fuel System . 628
Examine Fuel Circuit for Leakage 630
How to Examine Fuel System for Leakage 630
Handle Cylinder Cut-out Mode Operation 632
Handle No-Injection Cranking Operation 633
Examine and Adjust Air Conditioner Compressor Belt Tension 634
How to Examine Air Conditioner Compressor Belt Tension 634
How to Adjust Air Conditioner Compressor Belt Tension . 634
Examine Alternator Belt . 635
How to Examine Alternator Belt 635
Examine Automatic Tensioner . 637
How to Examine Automatic Tensioner 637
Write Correction for Ash in Soot Accumulation to Engine Controller 639
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 639
Examine SCR Related Functions . 640
Examine DEF Pump Raised Pressure 644
Examine Injection Volume from DEF Injector 647
Examine DEF Line Heater Relay 1 . 652
Examine DEF Line Heater Relay 2 . 655
Examine DEF Pump Heater Relay . 658
Examine DEF Tank Heater Valve . 661
Examine SCR Denitration Efficiency 664
Clean DEF Tank 667
How to Clean DEF Tank . 667
Clean DEF Tank Mounting Part 671
How to Clean DEF Tank Mounting Part . 671
Clean DEF Pump 673
How to Clean DEF Pump . 673
Adjust Decelerator Pedal 679
How to Adjust Decelerator Pedal . 679
Power Train . 681
Examine Power Train Oil Pressure 681
How to Examine Power Train Oil Pressure . 682
Adjust Transmission Output Shaft Speed Sensor . 693
How to Adjust Transmission Output Shaft Speed Sensor 693
Examine Brake Performance Simply 695
How to Examine Brake Performance Simply . 695
Adjust Brake Pedal 696
How to Adjust Brake Pedal . 696
Adjust Parking Brake Lever 698
How to Adjust Parking Brake Lever . 698
Move Machine by Parking Brake Release When Machine Does Not Travel 700
Move Machine with Hydraulic Type Parking Brake Release System . 700
Move Machine with Electric Type Parking Brake Release System 701
Undercarriage and Frame . 703
Adjust Idler Clearance 703
How to Adjust Idler Clearance . 703
Examine and Adjust Track Tension 704
How to Examine Track Tension 704
How to Adjust Track Tension . 704
Hydraulic System 705
Release Remained Pressure in Hydraulic Circuit 705
How to Release Remained Pressure in Hydraulic System 705
Examine and Adjust Work Equipment and HSS Oil Pressure 706
How to Examine Work Equipment and HSS Oil Pressure 706
Adjust Oil Pressure of Work Equipment and HSS . 710
Examine Oil Pressure of Control Circuit . 711
Examine Oil Pressure in Control Circuit . 711
Examine PPC Valve Outlet Pressure . 713
Examine Outlet Pressure in PPC Valve 713
Bleed Air from HSS Pump . 715
How to Bleed Air from HSS Pump 715
Examine and Adjust Play of Work Equipment PPC Valve . 716
How to Examine Play of Work Equipment PPC Valve . 716
How to Adjust Play of Work Equipment PPC Valve 717
Examine Cooling Fan Speed . 718
How to Examine Cooling Fan Speed 718
Examine Cooling Fan Circuit Oil Pressure 719
How to Examine Cooling Fan Circuit Oil Pressure . 719
Bleed Air in Cooling Fan Pump . 721
How to Bleed Air in Cooling Fan Pump 721
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 722
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder . 722
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder . 722
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 723
Examine Oil Leakage from Work Equipment Cylinder 724
How to Examine Internal Oil Leakage of Work Equipment Cylinder 724
Bleed Air from Work Equipment Cylinders . 726
Bleed Air from Work Equipment Cylinder 726
Work Equipment 728
Adjust Work Equipment Lock Lever 728
How to Adjust Work Equipment Lock Lever . 728
CAB Related Parts . 730
Examine and Adjust Operator Cab . 730
Examine Operator Cab 730
Adjust Operator Cab . 732
Electrical System . 735
Set and Operate Machine Monitor . 735
Operator Mode . 739
Function to Show Technician Identification Status Screen 739
Function to Show Operator Identification Input Screen . 739
Examine Function by LCD (Liquid Crystal Display) 740
Examine Function of Service Meter . 740
Usage Limitation and Change Maintenance Password 740
Service Mode 743
How to Operate Service Mode . 743
How to See Pre-defined Monitoring Information . 744
How to Examine Self-Define Monitor Information 750
Abnormality Record Menu . 760
How to See Maintenance Record . 764
Maintenance Mode Setting 765
Set Phone Number Entry 769
Default Menu 771
Diagnostic Tests Menu . 778
Adjustment Menu . 787
No-Injection Cranking Operation . 816
KOMTRAX Settings Menu . 818
Show Service Message 822
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) . 824
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 829
Start Up KOMTRAX System (Machine with Gateway Function Controller) 831
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) . 837
Adjust When Power Train Controller is Replaced 839
How to Adjust When Power Train Controller is Replaced . 839
Adjust Rearview Camera Angle 842
How to Adjust Rearview Camera Angle . 842
Handle Voltage Circuit of Engine Controller . 843
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 844
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) . 845
Examine Diodes 846
Examine Diodes by Digital Tester 846
How to Examine Diodes by Analog Tester 846
Pm Clinic . 847
Pm Clinic Service . 847
Pm Clinic Check Sheet: D65EX-18 . 849
Pm Clinic Check Sheet: D65PX-18 . 861
Pm Clinic Check Sheet: D65WX-18 . 873
Pm Clinic Check Sheet for Undercarriage: D65EX-18 . 885
Pm Clinic Check Sheet for Undercarriage: D65PX-18 . 892
Pm Clinic Check Sheet for Undercarriage: D65WX-18 . 898
40 Troubleshooting 905
Table of Contents . 906
Precautions Before Work . 916
Abbreviation List . 917
Related Information to Troubleshooting 923
General Troubleshooting Points 923
Troubleshooting Points for Urea SCR System 924
Sequence of Events in Troubleshooting . 938
Checks Before Troubleshooting . 940
Inspection Procedure Before Troubleshooting . 942
Walk-Around Check . 942
Test in Accordance with Testing Procedure . 944
How to Examine Electric Equipment . 944
Preparation for Troubleshooting of Electrical System 952
Procedure for Troubleshooting . 960
Symptom and Troubleshooting Numbers . 963
Information Shown in Troubleshooting Table 966
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 968
Connector List and Layout (Machine with KOMTRAX Terminal) . 970
Connector List and Layout (Machine with Gateway Function Controller) 986
Connector Contact Connection Table 1005
T-Branch Box and T-Branch Adapter Table .1045
Fuse Location Table (Machine with KOMTRAX Terminal) .1051
Fuse Location Table (Machine with Gateway Function Controller) 1054
Precautions When You Clean and Replace KDPF (KCSF and KDOC) .1057
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1061
Failure Code Table 1063
Troubleshooting by Failure Code (Display of Code) .1082
Failure Code [1500L0] .1082
Failure Code [15SAL1] .1083
Failure Code [15SALH] .1085
Failure Code [15SBL1] .1087
Failure Code [15SBLH] .1089
Failure Code [15SEL1] .1091
Failure Code [15SELH] .1093
Failure Code [15SFL1] .1095
Failure Code [15SFLH] .1097
Failure Code [15SGL1] .1099
Failure Code [15SGLH] .1101
Failure Code [15SJL1] .1103
Failure Code [15SJLH] .1105
Failure Code [1800MW] .1107
Failure Code [879AKA] .1108
Failure Code [879AKB] .1109
Failure Code [879BKA] .1110
Failure Code [879BKB] .1112
Failure Code [879CKA] .1114
Failure Code [879CKB] .1115
Failure Code [879DKZ] .1116
Failure Code [879EMC] .1118
Failure Code [879FMC] .1119
Failure Code [879GKX] .1120
Failure Code [989L00] .1122
Failure Code [989M00] .1123
Failure Code [989N00] .1124
Failure Code [A1U0N3] .1125
Failure Code [A1U0N4] .1127
Failure Code [A900FR] .1129
Failure Code [A900N6] .1130
Failure Code [A900NY] .1131
Failure Code [AA10NX] .1132
Failure Code [AB00KE] .1134
Failure Code [AQ10N3] .1136
Failure Code [AS00N3] .1138
Failure Code [AS00R2] .1140
Failure Code [AS00R3] .1141
Failure Code [AS00R4] .1142
Failure Code [AS00R5] .1143
Failure Code [AS00R6] .1144
Failure Code [AS00ZK] .1145
Failure Code [AS10KM] .1146
Failure Code [AS10NR] .1147
Failure Code [AS10NT] .1148
Failure Code [B@BAZG] .1149
Failure Code [B@BCNS] .1150
Failure Code [B@BCQA] .1151
Failure Code [B@BCZK] .1153
Failure Code [B@CENS] .1155
Failure Code [B@HANS] .1156
Failure Code [CA115] 1157
Failure Code [CA122] 1158
Failure Code [CA123] 1160
Failure Code [CA131] 1162
Failure Code [CA132] 1164
Failure Code [CA144] 1167
Failure Code [CA145] 1169
Failure Code [CA153] 1171
Failure Code [CA154] 1174
Failure Code [CA187] 1177
Failure Code [CA221] 1179
Failure Code [CA222] 1181
Failure Code [CA227] 1183
Failure Code [CA234] 1184
Failure Code [CA238] 1185
Failure Code [CA239] 1187
Failure Code [CA249] 1189
Failure Code [CA256] 1191
Failure Code [CA271] 1193
Failure Code [CA272] 1195
Failure Code [CA281] 1197
Failure Code [CA322] 1198
Failure Code [CA323] 1200
Failure Code [CA324] 1202
Failure Code [CA325] 1204
Failure Code [CA331] 1206
Failure Code [CA332] 1208
Failure Code [CA343] 1210
Failure Code [CA351] 1211
Failure Code [CA352] 1212
Failure Code [CA356] 1215
Failure Code [CA357] 1217
Failure Code [CA386] 1219
Failure Code [CA428] 1220
Failure Code [CA429] 1222
Failure Code [CA435] 1224
Failure Code [CA441] 1226
Failure Code [CA442] 1228
Failure Code [CA449] 1229
Failure Code [CA451] 1233
Failure Code [CA452] 1236
Failure Code [CA488] 1238
Failure Code [CA515] 1239
Failure Code [CA516] 1241
Failure Code [CA553] 1243
Failure Code [CA555] 1244
Failure Code [CA556] 1245
Failure Code [CA559] 1246
Failure Code [CA595] 1250
Failure Code [CA687] 1251
Failure Code [CA689] 1253
Failure Code [CA691] 1258
Failure Code [CA692] 1260
Failure Code [CA697] 1262
Failure Code [CA698] 1263
Failure Code [CA731] 1264
Failure Code [CA778] 1266
Failure Code [CA1117] .1271
Failure Code [CA1664] .1272
Failure Code [CA1669] .1275
Failure Code [CA1673] .1276
Failure Code [CA1677] .1277
Failure Code [CA1678] .1278
Failure Code [CA1682] .1279
Failure Code [CA1683] .1284
Failure Code [CA1684] .1286
Failure Code [CA1686] .1288
Failure Code [CA1691] .1289
Failure Code [CA1694] .1292
Failure Code [CA1695] .1295
Failure Code [CA1696] .1296
Failure Code [CA1712] .1298
Failure Code [CA1713] .1301
Failure Code [CA1714] .1303
Failure Code [CA1715] .1304
Failure Code [CA1776] .1305
Failure Code [CA1777] .1308
Failure Code [CA1843] .1311
Failure Code [CA1844] .1313
Failure Code [CA1879] .1316
Failure Code [CA1881] .1319
Failure Code [CA1883] .1322
Failure Code [CA1885] .1326
Failure Code [CA1887] .1328
Failure Code [CA1921] .1330
Failure Code [CA1922] .1333
Failure Code [CA1942] .1338
Failure Code [CA1993] .1339
Failure Code [CA2185] .1342
Failure Code [CA2186] .1344
Failure Code [CA2249] .1346
Failure Code [CA2265] .1347
Failure Code [CA2266] .1349
Failure Code [CA2271] .1351
Failure Code [CA2272] .1354
Failure Code [CA2288] .1357
Failure Code [CA2311] .1358
Failure Code [CA2349] .1359
Failure Code [CA2353] .1362
Failure Code [CA2357] .1364
Failure Code [CA2381] .1365
Failure Code [CA2382] .1368
Failure Code [CA2383] .1371
Failure Code [CA2386] .1374
Failure Code [CA2387] .1376
Troubleshooting Flowchart .1380
Failure Code [CA2555] .1381
Failure Code [CA2556] .1384
Failure Code [CA2637] .1387
Failure Code [CA2639] .1389
Failure Code [CA2771] .1392
Failure Code [CA2777] .1398
Failure Code [CA2976] .1401
Failure Code [CA3133] .1403
Failure Code [CA3134] .1405
Failure Code [CA3135] .1407
Failure Code [CA3142] .1411
Failure Code [CA3143] .1412
Failure Code [CA3144] .1413
Failure Code [CA3146] .1415
Failure Code [CA3147] .1416
Failure Code [CA3148] .1417
Failure Code [CA3151] .1419
Failure Code [CA3165] .1425
Failure Code [CA3229] .1427
Failure Code [CA3231] .1429
Failure Code [CA3232] .1431
Failure Code [CA3235] .1435
Failure Code [CA3239] .1437
Failure Code [CA3241] .1440
Failure Code [CA3242] .1443
Failure Code [CA3251] .1446
Failure Code [CA3253] .1448
Failure Code [CA3254] .1451
Failure Code [CA3255] .1454
Failure Code [CA3256] .1457
Failure Code [CA3311] .1459
Failure Code [CA3312] .1461
Failure Code [CA3313] .1464
Failure Code [CA3314] .1465
Failure Code [CA3315] .1466
Failure Code [CA3316] .1469
Failure Code [CA3317] .1470
Failure Code [CA3318] .1471
Failure Code [CA3319] .1474
Failure Code [CA3321] .1475
Failure Code [CA3322] .1477
Failure Code [CA3419] .1480
Failure Code [CA3421] .1482
Failure Code [CA3497] .1484
Failure Code [CA3498] .1485
Failure Code [CA3543] .1486
Failure Code [CA3545] .1493
Failure Code [CA3547] .1495
Failure Code [CA3558] .1496
Failure Code [CA3559] .1498
Failure Code [CA3562] .1500
Failure Code [CA3563] .1502
Failure Code [CA3567] .1505
Failure Code [CA3568] .1508
Failure Code [CA3571] .1515
Failure Code [CA3572] .1517
Failure Code [CA3574] .1519
Failure Code [CA3575] .1522
Failure Code [CA3577] .1524
Failure Code [CA3578] .1526
Failure Code [CA3582] .1528
Failure Code [CA3583] .1537
Failure Code [CA3596] .1539
Failure Code [CA3649] .1542
Failure Code [CA3681] .1544
Failure Code [CA3682] .1546
Failure Code [CA3713] .1549
Failure Code [CA3717] .1552
Failure Code [CA3718] .1553
Failure Code [CA3725] .1554
Failure Code [CA3741] .1557
Failure Code [CA3748] .1558
Failure Code [CA3751] .1561
Failure Code [CA3755] .1563
Failure Code [CA3866] .1565
Failure Code [CA3867] .1569
Failure Code [CA3868] .1572
Failure Code [CA3899] .1576
Failure Code [CA3911] .1578
Failure Code [CA3912] .1582
Failure Code [CA3932] .1584
Failure Code [CA3933] .1586
Failure Code [CA3934] .1588
Failure Code [CA3935] .1591
Failure Code [CA3936] .1593
Failure Code [CA4151] .1595
Failure Code [CA4152] .1599
Failure Code [CA4155] .1603
Failure Code [CA4156] .1606
Failure Code [CA4157] .1609
Failure Code [CA4158] .1611
Failure Code [CA4159] .1612
Failure Code [CA4161] .1613
Failure Code [CA4162] .1615
Failure Code [CA4163] .1618
Failure Code [CA4164] .1620
Failure Code [CA4165] .1622
Failure Code [CA4166] .1624
Failure Code [CA4168] .1626
Failure Code [CA4169] .1629
Failure Code [CA4171] .1631
Failure Code [CA4249] .1634
Failure Code [CA4251] .1636
Failure Code [CA4259] .1638
Failure Code [CA4261] .1641
Failure Code [CA4277] .1644
Failure Code [CA4281] .1648
Failure Code [CA4459] .1652
Failure Code [CA4461] .1655
Failure Code [CA4658] .1658
Failure Code [CA4731] .1662
Failure Code [CA4732] .1663
Failure Code [CA4739] .1664
Failure Code [CA4768] .1665
Failure Code [CA4769] .1667
Failure Code [CA4842] .1670
Failure Code [CA4952] (Machine with KOMTRAX Terminal) .1674
Failure Code [CA4952] (Machine with Gateway Function Controller) 1676
Failure Code [CA5115] .1678
Failure Code [CA5383] .1681
Failure Code [D130KA] .1683
Failure Code [D130KB] .1686
Failure Code [D19JKZ] .1688
Failure Code [D811MC] (Machine with KOMTRAX Terminal) .1691
Failure Code [D811MC] (Machine with Gateway Function Controller) 1692
Failure Code [D862KA] (Machine with KOMTRAX Terminal) .1693
Failure Code [D862KA] (Machine with Gateway Function Controller) 1694
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) .1695
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1697
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) .1699
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1701
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) .1703
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1705
Failure Code [D8G1KT] .1707
Failure Code [D8G6KT] .1708
Failure Code [DAF0MB] .1709
Failure Code [DAF0MC] .1710
Failure Code [DAF8KB] .1711
Failure Code [DAF9KQ] .1712
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) .1713
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1714
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) .1715
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1717
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) .1719
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1721
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) .1723
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1724
Failure Code [DAQW00] .1725
Failure Code [DAZ9KQ] .1726
Failure Code [DAZQKR] .1727
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) .1728
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1733
Failure Code [DB2RKR] .1738
Failure Code [DBE0KT] .1743
Failure Code [DBE1KK] .1744
Failure Code [DBE2KK] .1747
Failure Code [DBE5KK] .1750
Failure Code [DBE6KK] .1752
Failure Code [DBE7KK] .1754
Failure Code [DBE9KQ] .1756
Failure Code [DBELKA] .1757
Failure Code [DBELKB] .1759
Failure Code [DBEQKR] .1761
Failure Code [DBERKR] .1762
Failure Code [DD12KA] .1764
Failure Code [DD12KB] .1766
Failure Code [DD13KA] .1768
Failure Code [DD13KB] .1770
Failure Code [DD14KA] .1772
Failure Code [DD14KB] .1774
Failure Code [DDKFL4] .1776
Failure Code [DDKGL4] .1778
Failure Code [DDKHKA] .1780
Failure Code [DDKHKB] .1782
Failure Code [DDN7KA] .1784
Failure Code [DDN7KB] .1786
Failure Code [DDNLKA] .1788
Failure Code [DDNLKB] .1790
Failure Code [DGS1KA] .1792
Failure Code [DGS1KX] .1794
Failure Code [DGT1KA] .1796
Failure Code [DGT1KX] .1799
Failure Code [DH21KA] .1801
Failure Code [DH21KY] .1803
Failure Code [DHA4KA] .1805
Failure Code [DHAAMA] .1807
Failure Code [DHACMA] .1809
Failure Code [DHTDKA] .1811
Failure Code [DHTDKY] .1813
Failure Code [DK10KA] .1815
Failure Code [DK10KB] .1818
Failure Code [DK30KA] .1820
Failure Code [DK30KX] .1823
Failure Code [DK30KY] .1824
Failure Code [DK30KZ] .1826
Failure Code [DK30L8] .1827
Failure Code [DK31KA] .1828
Failure Code [DK31KY] .1831
Failure Code [DK40KA] .1833
Failure Code [DK40KY] .1835
Failure Code [DK55KX] .1837
Failure Code [DK55KZ] .1838
Failure Code [DK55L8] .1839
Failure Code [DK56KA] .1840
Failure Code [DK56KY] .1842
Failure Code [DK57KA] .1844
Failure Code [DK57KY] .1846
Failure Code [DKH1KA] .1848
Failure Code [DKH1KY] .1851
Failure Code [DLM3KA] .1853
Failure Code [DLM3MB] .1855
Failure Code [DLT3KA] .1856
Failure Code [DLT3KB] .1858
Failure Code [DR21KX] .1860
Failure Code [DR31KX] .1861
Failure Code [DV20KB] .1862
Failure Code [DW5AKA] .1864
Failure Code [DW5AKB] .1866
Failure Code [DW5AKY] .1868
Failure Code [DW7BKA] .1870
Failure Code [DW7BKB] .1872
Failure Code [DW7BKY] .1874
Failure Code [DWN1KA] .1875
Failure Code [DWN1KB] .1877
Failure Code [DWN1KY] .1879
Failure Code [DWN2KA] .1881
Failure Code [DWN2KB] .1883
Failure Code [DWN2KY] .1885
Failure Code [DWN5KA] .1886
Failure Code [DWN5KB] .1888
Failure Code [DWN5KY] .1889
Failure Code [DXA2KA] .1891
Failure Code [DXA2KB] .1893
Failure Code [DXA2KY] .1895
Failure Code [DXH1KA] .1896
Failure Code [DXH1KB] .1898
Failure Code [DXH1KY] .1900
Failure Code [DXH4KA] .1902
Failure Code [DXH4KB] .1904
Failure Code [DXH4KY] .1906
Failure Code [DXH5KA] .1908
Failure Code [DXH5KB] .1910
Failure Code [DXH5KY] .1912
Failure Code [DXH6KA] .1914
Failure Code [DXH6KB] .1916
Failure Code [DXH6KY] .1918
Failure Code [DXH7KA] .1920
Failure Code [DXH7KB] .1922
Failure Code [DXH7KY] .1924
Failure Code [DXH8KA] .1926
Failure Code [DXH8KB] .1928
Failure Code [DXH8KY] .1930
Failure Code [DXJ4KA] .1932
Failure Code [DXJ4KB] .1934
Failure Code [DXJCKA] .1936
Failure Code [DXJCKB] .1938
Failure Code [DXJCKY] .1940
Failure Code [DXJDKA] .1942
Failure Code [DXJDKB] .1944
Failure Code [DXJDKY] .1946
Failure Code [F313KA] .1948
Failure Code [F313KB] .1949
Failure Code [F318KB] .1950
Failure Code [F318KY] .1951
Troubleshooting of Electrical System (E-Mode) .1952
Engine Does Not Start (Engine Does Not Crank) .1952
Manual Preheating System Does Not Operate .1959
Automatic Preheating System Does Not Operate 1962
While Preheating is in Operation, Preheating Monitor Does Not Come On .1964
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1966
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On .1970
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1971
Charge Level Monitor Comes On in Red While Engine is in Operation .1972
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .1974
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1975
Power Train Oil Temperature Monitor Comes On in Red While Engine Runs .1976
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1977
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1978
DEF Level is Not Shown Correctly 1979
Fuel Gauge Does Not Show Normally .1982
Power Train Oil Temperature Gauge Does Not Show Correct Temperature .1984
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature .1985
Operation Mode Does Not Change 1986
Gear Shift Mode Does Not Change .1987
When You Operate Customize Switch Does Not Show Customize Screen 1988
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 1989
Some Areas of Machine Monitor Screen are Not Shown 1990
REVERSE Slow Mode Function Does Not Operate Correctly .1991
Alarm Buzzer Does Not Operate or Does Not Stop Operation 1992
Service Meter is Not Shown While Starting Switch is in OFF Position .1993
Service Mode Cannot be Selected .1994
Horn Does Not Sound .1995
Horn Does Not Stop 1997
Backup Alarm Does Not Sound .1998
Backup Alarm Does Not Stop Operation 2000
Headlamp Does Not Come On .2001
Rear Lamp Does Not Come On 2005
No Wiper Operates .2008
Front Wiper Does Not Operate 2012
Rear Wiper Does Not Operate .2015
Left Door Wiper Does Not Operate 2018
Right Door Wiper Does Not Operate .2021
Front Washer Does Not Operate .2024
Rear Washer Does Not Operate 2026
Left Door Washer Does Not Operate .2028
Right Door Washer Does Not Operate 2030
KOMTRAX System Does Not Operate Correctly .2032
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2033
Information Shown in Troubleshooting Table (H-Mode) .2033
System Chart of Hydraulic and Mechanical Systems 2034
Failure Mode and Cause Table 2036
Machine Lacks Power (Drawbar Pull is Not Sufficient) 2044
Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2046
Machine Does Not Move Off at All Gear Speeds 2047
Machine Travels Only in One Direction, Forward or in Reverse 2049
Large Time Lag is in Gear Shifting or Directional Change 2050
Brake Does Not Work .2052
Power Train Oil Overheats .2053
Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor .2055
Torque Converter Lockup Clutch Does Not Engage 2056
Machine Cannot be Steered (Machine Does Not Turn Left or Right) .2057
Steering Speed or Power is Not Sufficient .2058
All Work Equipment Operate Slowly .2059
All Work Equipment Do Not Operate .2060
Blade Lift Speed or Power is Low 2061
Blade Tilt Speed or Power is Low 2062
Blade Angle Speed or Power is Low .2063
Ripper Lift Speed or Power is Low .2064
Hydraulic Drift of Blade Lift is Large 2065
Hydraulic Drift of Tilted Blade is Large 2066
Hydraulic Drift of Lifted Ripper is Large .2067
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2068
Unusual Noise is Heard from Around Fan 2070
Troubleshooting of Engine (S-Mode) 2071
Information Shown in Troubleshooting Table (S-Mode) .2071
Engine Does Not Crank When Starting Switch is Turned to Start Position 2072
Engine Cranks but No Exhaust Smoke Comes Out 2073
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2074
Engine Startability is Unsatisfactory .2076
Engine Does Not Pick Up Smoothly 2078
Engine Stops During Operation .2080
Engine Does Not Rotate Smoothly .2082
Engine Lacks Output (or Lacks Power) 2083
KDPF Becomes Clogged in a Short Time 2085
Engine Oil Consumption is Excessive .2087
Engine Oil Becomes Dirty Quickly 2088
Fuel Consumption is Excessive .2089
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2090
Engine Oil Pressure Drops .2091
Fuel Mixes Into Engine Oil 2093
Water Mixes Into Engine Oil (Milky) .2094
Coolant Temperature Increases Too High (Overheat) .2095
Unusual Noise is Heard 2096
Vibration is Excessive 2097
Air Cannot be Bled from Fuel Circuit 2098
Active Regeneration is Done Frequently 2099
Active Regeneration Continues Long 2101
White Smoke is Exhausted During Active Regeneration .2102
DEF Consumption is Excessive 2103
There is an Unusual Smell (Irritating Odor) .2105
Foreign Materials Enter DEF (DEF Increases) .2106
50 Disassembly and Assembly .2107
Table of Contents .2108
Precautions Before Work .2114
Abbreviation List .2115
Related Information on Disassembly and Assembly .2121
How to Read This Manual .2121
Coating Materials List 2122
Special Tool List .2127
Sketches of Special Tools .2149
Engine and Cooling System .2170
Remove and Install Supply Pump Assembly .2170
Remove Supply Pump Assembly .2170
Install Supply Pump Assembly 2174
Remove and Install Injector Assembly 2179
How to Remove Injector Assembly .2180
How to Install Injector Assembly 2187
Remove and Install Cylinder Head Assembly .2198
How to Remove Cylinder Head Assembly 2199
How to Install Cylinder Head Assembly .2209
Remove and Install EGR Valve Assembly .2225
Remove EGR Valve Assembly .2225
Install EGR Valve Assembly 2226
Remove and Install EGR Cooler Assembly 2227
How to Remove EGR Cooler Assembly .2227
How to Install EGR Cooler Assembly 2228
Remove and Install Starter Assembly .2230
Remove Starting Motor Assembly 2230
Install Starting Motor Assembly .2232
Remove and Install Alternator Belt 2235
Remove Alternator Belt 2235
Install Alternator Belt .2236
Remove and Install Automatic Tensioner 2238
Remove Automatic Tensioner 2238
Install Automatic Tensioner .2238
Remove and Install Expansion Tank Assembly 2239
How to Remove Expansion Tank Assembly .2239
How to Install Expansion Tank Assembly 2243
Remove and Install Radiator Assembly 2248
How to Remove Radiator Assembly .2248
How to Install Radiator Assembly 2251
Remove and Install Hydraulic Oil Cooler Assembly 2255
How to Remove Hydraulic Oil Cooler Assembly .2255
How to Install Hydraulic Oil Cooler Assembly 2257
Remove and Install Aftercooler Assembly .2261
Remove Aftercooler Assembly .2261
Install Aftercooler Assembly 2263
Remove and Install Power Train Oil Cooler Assembly 2266
How to Remove Power Train Oil Cooler Assembly .2266
How to Install Power Train Oil Cooler Assembly 2268
Remove and Install Cooling Fan Drive Assembly .2271
Remove Cooling Fan Drive Assembly .2271
Install Cooling Fan Drive Assembly 2272
Remove and Install Cooling Fan Motor Assembly .2275
Remove Cooling Fan Motor Assembly .2275
Install Cooling Fan Motor Assembly 2277
Remove and Install Engine Assembly 2279
Remove Engine Assembly 2279
Install Engine Assembly .2283
Remove and Install Engine Front Oil Seal 2289
How to Remove Engine Front Oil Seal .2289
How to Install Engine Front Oil Seal 2291
Remove and Install Engine Rear Oil Seal .2295
How to Remove Engine Rear Oil Seal 2295
How to Install Engine Rear Oil Seal .2299
Remove and Install Engine Hood Assembly .2307
How to Remove Engine Hood Assembly 2307
How to Install Engine Hood Assembly .2311
Remove and Install Fuel Tank Assembly .2315
Remove Fuel Tank Assembly .2315
Install Fuel Tank Assembly 2318
Remove and Install DEF Tank Assembly 2321
How to Remove DEF Tank Assembly .2322
How to Install DEF Tank Assembly 2326
Remove and Install DEF Tank Sensor Flange Assembly 2330
How to Remove DEF Tank Sensor Flange Assembly .2331
How to Install DEF Tank Sensor Flange Assembly 2335
Remove and Install DEF Tank Sensor 2342
Remove DEF Tank Sensor 2342
Install DEF Tank Sensor .2343
Remove and Install DEF Tank Strainer 2350
Remove DEF Tank Strainer 2350
Install DEF Tank Strainer .2350
Remove and Install KDPF Assembly 2351
How to Remove KDPF Assembly .2351
How to Install KDPF Assembly 2355
Disassemble and Assemble KDPF Assembly 2359
Disassemble KDPF Assembly .2359
Assemble KDPF Assembly 2363
Remove and Install SCR Assembly .2369
How to Remove SCR Assembly 2369
How to Install SCR Assembly .2371
Remove and Install KDPF and SCR Assembly 2374
How to Remove KDPF and SCR Assembly .2374
Install KDPF and SCR Assembly .2381
Remove and Install KCCV Assembly 2388
Remove KCCV Assembly 2388
Install KCCV Assembly .2390
Remove and Install DEF Mixing Tube 2392
Remove DEF Mixing Tube 2392
Install DEF Mixing Tube .2395
Remove and Install DEF Injector .2400
Remove DEF Injector .2400
Install DEF Injector 2403
Remove and Install DEF Pump .2407
Remove DEF Pump .2407
Install DEF Pump 2410
Remove and Install DEF Hose .2413
Remove DEF Hose .2413
Install DEF Hose 2418
Remove and Install Air Cleaner Assembly .2423
Remove Air Cleaner Assembly .2423
Install Air Cleaner Assembly 2424
Remove and Install Air Conditioner Compressor Assembly 2426
Remove Air Conditioner Compressor Assembly 2426
How to Install Air Conditioner Compressor Assembly 2428
Remove and Install Air Conditioner Condenser Assembly .2431
How to Remove Air Conditioner Condenser Assembly 2431
How to Install Air Conditioner Condenser Assembly .2433
Power Train .2435
Remove and Install Damper Assembly 2435
How to Remove Damper Assembly .2435
How to Install Damper Assembly 2438
Remove and Install Power Train Unit Assembly 2443
Remove Power Train Unit Assembly 2443
How to Install Power Train Unit Assembly 2448
Disconnect and Connect Power Train Unit Assembly 2454
How to Disconnect Power Train Unit Assembly .2454
Connect Power Train Unit Assembly .2459
Disassemble and Assemble PTO Assembly .2465
Disassemble PTO Assembly 2465
Assemble PTO Assembly .2468
Disassemble and Assemble Torque Converter Assembly 2472
Disassemble Torque Converter Assembly .2473
Assemble Torque Converter Assembly 2479
Disassemble and Assemble Transmission Assembly 2488
Disassemble Transmission Assembly .2489
Assemble Transmission Assembly 2507
Disassemble and Assemble HSS Assembly .2520
Disassemble HSS Assembly 2522
Assemble HSS Assembly .2533
Remove and Install HSS Motor Assembly .2550
Remove HSS Motor Assembly .2550
How to Install HSS Motor Assembly .2552
Remove and Install Final Drive Assembly .2555
Remove Final Drive Assembly .2555
Install Final Drive Assembly 2558
Disassemble and Assemble Final Drive Assembly .2561
Disassemble Final Drive Assembly 2562
Assemble Final Drive Assembly .2567
Undercarriage and Frame .2575
Remove and Install Track Frame Assembly .2575
Remove Track Frame Assembly .2575
Install Track Frame Assembly 2577
Remove and Install Idler Assembly .2580
Remove Idler Assembly .2580
Install Idler Assembly 2581
Disassemble and Assemble Idler Assembly .2583
Disassemble Idler Assembly 2583
Assemble Idler Assembly .2585
Remove and Install Recoil Spring Assembly .2589
Remove Recoil Spring Assembly .2589
Install Recoil Spring Assembly 2589
Disassemble and Assemble Recoil Spring Assembly .2591
Disassemble Recoil Spring Assembly 2591
Assemble Recoil Spring Assembly .2594
Remove and Install Track Roller Assembly 2597
Remove Track Roller Assembly 2597
Install Track Roller Assembly .2598
Disassemble and Assemble Track Roller Assembly 2599
Disassemble Track Roller Assembly .2599
Assemble Track Roller Assembly 2601
Remove and Install Carrier Roller Assembly 2604
Remove Carrier Roller Assembly 2604
Install Carrier Roller Assembly .2605
Disassemble and Assemble Carrier Roller Assembly 2606
Disassemble Carrier Roller Assembly .2606
Assemble Carrier Roller Assembly 2607
Remove and Install Pivot Shaft Assembly .2610
Remove Pivot Shaft Assembly .2610
Install Pivot Shaft Assembly 2611
Separate and Connect Track Assembly .2612
Examine Before Separation of Track Assembly .2612
Separate Track Assembly (Standard) 2612
How to Separate Track Assembly (When Track Frame Has Internal Defect) .2613
Install Track Assembly 2614
Separate and Connect PLUS Type Track Assembly .2617
Separate PLUS Type Track Assembly Generally .2617
Install PLUS Type Track Assembly 2617
Disassemble and Assemble Track Assembly Generally .2618
How to Disassemble Full Track Shoes Assembly 2618
How to Assemble Full Track Shoes Assembly .2621
Disassemble and Assemble PLUS Type Track Assembly Generally .2633
Disassemble PLUS Type Track Assembly Generally 2634
How to Assemble PLUS Type Track Shoes Assembly Generally 2635
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2650
Disassemble One Track Link Assembly in Field (Track Assembly) .2651
Assemble One Track Link Assembly in Field (Track Assembly) 2652
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2659
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) .2660
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2662
Remove and Install Equalizer Bar Assembly .2666
Remove Equalizer Bar Assembly .2666
Install Equalizer Bar Assembly 2667
Disassemble and Assemble Equalizer Bar Bushing 2669
Disassemble Equalizer Bar Bushing .2669
Assemble Equalizer Bar Bushing 2669
Hydraulic System 2671
Remove and Install Hydraulic Tank Assembly 2671
Remove Hydraulic Tank Assembly 2671
How to Install Hydraulic Tank Assembly 2674
Remove and Install HSS Pump and Cooling Fan Pump Assembly .2679
How to Remove HSS Pump and Cooling Fan Pump Assembly 2679
How to Install HSS Pump and Cooling Fan Pump Assembly .2680
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2683
Remove Power Train Pump and Steering Lubrication Pump Assembly 2683
Install Power Train Pump and Steering Lubrication Pump Assembly .2685
Remove and Install Scavenging Pump Assembly .2688
Remove Scavenging Pump Assembly .2688
Install Scavenging Pump Assembly 2688
Remove and Install 5 Spool Control Valve Assembly .2690
How to Remove 5 Spool Control Valve Assembly 2690
How to Install 5 Spool Control Valve Assembly .2692
Remove and Install 4 Spool Control Valve Assembly .2695
How to Remove 4 Spool Control Valve Assembly 2695
How to Install 4 Spool Control Valve Assembly .2697
Disassemble and Assemble Blade PPC Valve 2701
How to Disassemble Blade PPC Valve 2701
How to Assemble Blade PPC Valve .2701
Disassemble and Assemble Ripper PPC Valve .2703
How to Disassemble Ripper PPC Valve .2703
How to Assemble Ripper PPC Valve 2703
Work Equipment 2705
Remove and Install Straight Tilt Power Pitch Dozer Blade Assembly .2705
How to Remove Straight Tilt Power Pitch Dozer Blade Assembly 2705
How to Install Straight Tilt Power Pitch Dozer Blade Assembly .2707
Remove and Install Power Angle Power Tilt Dozer Blade Assembly 2711
How to Remove Power Angle Power Tilt Dozer Blade Assembly .2711
How to Install Power Angle Power Tilt Dozer Blade Assembly 2713
Remove and Install Ripper Assembly 2716
Remove Ripper Assembly 2716
Install Ripper Assembly .2719
How to Disassemble and Assemble Work Equipment Cylinder Assembly 2722
How to Disassemble Work Equipment Cylinder Assembly .2723
How to Assemble Work Equipment Cylinder Assembly 2726
CAB Related Parts .2731
Remove and Install Operator Cab Assembly 2731
How to Remove Operator Cab Assembly .2731
Install Operator CAB Assembly .2738
Remove and Install Operator Cab Glass (Adhered Glass) .2747
Remove Operator CAB Glass (Adhered Glass) .2747
Install Operator CAB Glass (Adhered Glass) 2748
Remove and Install Air Conditioner Unit Assembly 2753
Remove Air Conditioner Unit Assembly 2753
Install Air Conditioner Unit Assembly .2758
Remove and Install Operator Seat 2764
Remove Operator’s Seat 2764
Install Operator’s Seat .2766
How to Remove and Install Seat Belt .2768
How to Remove Seat Belt .2768
How to Install Seatbelt .2769
Electrical System .2770
Remove and Install Engine Controller Assembly .2770
Remove Engine Controller Assembly .2770
Install Engine Controller Assembly 2771
Remove and Install Power Train Controller Assembly 2774
Remove Power Train Controller Assembly 2774
Install Power Train Controller Assembly .2775
Remove and Install Machine Monitor Assembly .2777
Remove Machine Monitor Assembly .2777
Install Machine Monitor Assembly 2778
Remove and Install Mass Air Flow and Temperature Sensor .2780
How to Remove Mass Air Flow and Temperature Sensor 2780
How to Install Mass Air Flow and Temperature Sensor .2781
Remove and Install KCCV Crankcase Pressure Sensor .2782
How to Remove KCCV Crankcase Pressure Sensor 2782
How to Install KCCV Crankcase Pressure Sensor .2783
Remove and Install SCR Temperature Sensor .2784
Remove SCR Temperature Sensor .2784
Install SCR Temperature Sensor 2785
Remove and Install Rearview Camera 2787
Remove Rearview Camera 2787
Install Rearview Camera .2787
Remove and Install KOMTRAX Terminal Assembly 2789
Remove KOMTRAX Terminal Assembly 2789
Install KOMTRAX Terminal Assembly .2791
Remove and Install Gateway Function Controller Assembly .2793
How to Remove Gateway Function Controller Assembly 2793
How to Install Gateway Function Controller Assembly .2796
Remove and Install Communication Terminal .2800
How to Remove Communication Terminal 2800
How to Install Communication Terminal .2803
60 Maintenance Standard .2807
Table of Contents .2808
Abbreviation List .2810
Engine and Cooling System .2816
Maintenance Standard for Engine Mount .2816
Maintenance Standard for Damper .2817
Maintenance Standard for Cooling System .2819
Maintenance Standard for Cooling Fan Pump .2821
Maintenance Standard for Servo Valve 2822
Maintenance Standard for Cooling Fan Motor 2823
Power Train .2825
Maintenance Standard for Universal Joint 2825
Maintenance Standard for Power Train Mount 2826
Maintenance Standard for Torque Converter and PTO .2828
Maintenance Standard for Lockup Clutch ECMV .2831
Maintenance Standard for Transmission .2832
Maintenance Standard for Transmission Control Valve .2837
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV .2838
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 2839
Maintenance Standard for Transmission Lubrication Relief Valve 2840
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake .2841
Maintenance Standard for Brake Valve 2846
Maintenance Standard for Final Drive 2848
Maintenance Standard for Sprocket for Conventional Type Track Shoes .2850
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2851
Maintenance Standard for Sprocket for PLUS Type Track Shoes .2853
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2854
Undercarriage and Frame .2856
Maintenance Standard for Main Frame .2856
Maintenance Standard for Suspension .2857
Maintenance Standard for Track Frame and Idler Cushion 2859
Maintenance Standard for Idler 2861
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2863
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2864
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2865
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2866
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes .2867
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes .2868
Maintenance Standard for Conventional Type Track Shoes 2869
Maintenance Standard for PLUS Type Track Shoes 2871
Maintenance Standard for Single Shoes .2873
Maintenance Standard for Swamp Shoes 2874
Hydraulic System 2875
Maintenance Standard for Hydraulic Tank .2875
Maintenance Standard for Scavenging Pump 2876
Maintenance Standard for Steering Lubrication Pump and Power Train Pump .2877
Maintenance Standard for Work Equipment and HSS Pump 2878
Maintenance Standard for PC-EPC Valve .2879
Maintenance Standard for HSS Motor 2880
Maintenance Standard for Control Valve 2882
Maintenance Standard for Blade PPC Valve 2890
Maintenance Standard for Ripper PPC Valve .2892
Maintenance Standard for Angle Control EPC Valve 2894
Maintenance Standard for Quick Drop Valve .2895
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer and Angle Dozer Series) .2897
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Tilt Pitch Dozer Series) .2898
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Angle Power Tilt Dozer Series) .2899
Work Equipment 2900
Maintenance Standard for Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series) 2900
Maintenance Standard for Front Work Equipment (For Power Angle Power Tilt Dozer Series) .2903
Maintenance Standard for Front Work Equipment (Angle Dozer Series) 2906
Maintenance Standard for Cutting Edge and End Bit .2909
Maintenance Standard for Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series) 2911
Maintenance Standard for Blade Lift Cylinder (For Power Angle Power Tilt Dozer Series) 2912
Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series) 2913
Maintenance Standard for Blade Tilt Cylinder (For Power Angle Power Tilt Dozer Series) 2914
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series) .2915
Maintenance Standard for Blade Angle Cylinder (For Power Angle Power Tilt Dozer Series) .2916
Maintenance Standard for Fixed Multi-Shank Ripper .2917
Maintenance Standard for Ripper Lift Cylinder .2918
CAB Related Parts .2919
Maintenance Standard for CAB Mount 2919
80 Appendix .2921
Table of Contents .2922
Precautions Before Work .2924
Abbreviation List .2925
Air Conditioner System 2931
Precautions for Refrigerant .2931
Air Conditioner Component .2932
Specifications of Air Conditioner .2934
Structure and Function of Refrigeration Cycle .2935
Outline of Refrigeration Cycle 2936
Component Parts of Air Conditioner System .2938
Air Conditioner Unit 2938
Configuration Diagram of Air Conditioner Unit .2938
Function of Air Conditioner Unit 2940
Component Parts of Air Conditioner Unit .2942
Function of Evaporator as Air Conditioner Unit Component 2943
Function of Heater Core as Air Conditioner Unit Component .2943
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .2943
Function of Servo Motor as Air Conditioner Unit Component .2943
Structure of Expansion Valve as Air Conditioner Unit Component 2944
Function of Expansion Valve as Air Conditioner Unit Component .2944
Operate Expansion Valve as Air Conditioner Unit Component .2944
Function of Dual Pressure Switch 2945
Air Conditioner Controller 2946
Structure of Air Conditioner Controller .2946
Compressor 2947
Structure of Compressor .2947
Specifications of Compressor 2947
Function of Compressor 2947
Condenser .2948
Structure of Standard Core Condenser 2948
Specifications of Standard Core Condenser .2948
Function of Standard Core Condenser .2948
Structure of Wide Core Condenser 2949
Specifications of Wide Core Condenser .2949
Function of Wide Core Condenser .2949
Receiver Drier 2950
Structure of Receiver Dryer .2950
Specifications of Receiver Dryer 2950
Function of Receiver Dryer 2950
Air Conditioner Related Sensors .2951
Structure of Sunlight Sensor 2951
Function of Sunlight Sensor .2951
Structure of Outside Temperature Sensor .2951
Function of Outside Air Temperature Sensor 2951
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .2953
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2955
System Diagram of Air Conditioner .2957
Input and Output Signals of Air Conditioner Controller 2958
Function of Air Conditioner Controller 2959
Locations of Air Conditioner Parts and Layout of Connectors .2960
Examine Air Leakage (Duct) 2969
How to Examine Air Leakage (Duct) .2969
Explanation for Test of Air Conditioner with Self-Diagnosis Function 2972
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .2973
Examine Vent (Mode) Changeover 2974
How to Examine Vent (Mode) Changeover .2974
Examine Fresh/Recirc Air Changeover .2975
How to Examine Fresh/Recirc Air Changeover 2975
Examine Sunlight Sensor .2976
How to Examine Sunlight Sensor 2976
Examine Refrigerant (Dual) Pressure Switch 2977
How to Examine Refrigerant (Dual) Pressure Switch .2977
Examine Relay .2978
How to Examine Relay 2978
Air Conditioner Troubleshooting Chart 1 .2979
Air Conditioner Troubleshooting Chart 2 .2980
Information Shown in Troubleshooting Table 2983
Failure Code [879AKA] .2984
Failure Code [879AKB] .2985
Failure Code [879BKA] .2986
Failure Code [879BKB] .2988
Failure Code [879CKA] .2990
Failure Code [879CKB] .2991
Failure Code [879DKZ] .2992
Failure Code [879EMC] .2994
Failure Code [879FMC] .2995
Failure Code [879GKX] .2996
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2998
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .3000
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3004
Troubleshooting for Fresh/Recirc Air Changeover .3006
Troubleshooting by Gauge Pressure .3008
Connect Service Tool 3011
How to Connect Service Tool .3011
Precautions for Disconnection and Connection of Air Conditioner Piping 3013
Handle Compressor Oil .3015
90 Circuit Diagrams .3017
Table of Contents .3018
Abbreviation List .3019
Hydraulic Circuit Diagram .3025
Symbols Used in Hydraulic Circuit Diagram .3025
Hydraulic Circuit Diagram (For Straight Tilt and SIGMADOZER) 3029
Hydraulic Circuit Diagram (For Straight Tilt Power Pitch Dozer) .3031
Hydraulic Circuit Diagram (For Power Angle Power Tilt Dozer) 3033
Hydraulic Circuit Diagram (For Straight Tilt and SIGMADOZER) (3D Machine Control Spec) 3035
Hydraulic Circuit Diagram (For Straight Tilt Power Pitch Dozer) (3D Machine Control Spec) .3037
Hydraulic Circuit Diagram (For Power Angle Power Tilt Dozer) (3D Machine Control Spec) 3039
Power Train Hydraulic Circuit Diagram .3041
Electrical Circuit Diagram 3043
Symbols Used in Electric Circuit Diagram 3043
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/16) .3047
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/16) .3049
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/16) .3051
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/16) .3053
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/16) .3055
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/16) .3057
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/16) .3059
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/16) .3061
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/16) .3063
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/16) 3065
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/16) 3067
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (12/16) 3069
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (13/16) 3071
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (14/16) 3073
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (15/16) 3075
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (16/16) 3077
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/18) 3079
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/18) 3081
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/18) 3083
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/18) 3085
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/18) 3087
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/18) 3089
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/18) 3091
Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/18) 3093
Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/18) 3095
Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/18) .3097
Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/18) .3099
Electrical Circuit Diagram (Machine with Gateway Function Controller) (12/18) .3101
Electrical Circuit Diagram (Machine with Gateway Function Controller) (13/18) .3103
Electrical Circuit Diagram (Machine with Gateway Function Controller) (14/18) .3105
Electrical Circuit Diagram (Machine with Gateway Function Controller) (15/18) .3107
Electrical Circuit Diagram (Machine with Gateway Function Controller) (16/18) .3109
Electrical Circuit Diagram (Machine with Gateway Function Controller) (17/18) .3111
Electrical Circuit Diagram (Machine with Gateway Function Controller) (18/18) .3113
Index 3115

DESCRIPTION:

Komatsu Bulldozer D65EX-18,D65PX-18,D65WX-18 Shop Manual SEN06715-09 – PDF DOWNLOAD

• SERIAL NUMBERS
  D65EX- 91310      and up
  D65PX- 91310      and up
  D65WX-91310      and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “Ad Blue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “Ad Blue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “Ad Blue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode

G.B 27/12/24