Komatsu Bulldozer D65EX -18,D65PX -18,D65WX-18 Shop Manual SEN06900-04 PDF

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Komatsu Bulldozer D65EX -18,D65PX -18,D65WX-18 Shop Manual SEN06900-04  – PDF DOWNLOAD

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Komatsu Bulldozer D65EX -18,D65PX -18,D65WX-18 Shop Manual SEN06900-04  – PDF DOWNLOAD

Language : English
Pages : 490
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer D65EX -18,D65PX -18,D65WX-18 Shop Manual SEN06900-04  – PDF DOWNLOAD

• SERIAL NUMBERS
  D65EX- 96001            and up
  D65PX- 96001            and up
  D65WX-96001            and up

Cover 1
00 Index and Foreword . 3
Index . 4
Foreword, Safety, Basic Information . 22
How to Read the Shop Manual . 22
Safety Notice for Operation . 24
Precautions to Prevent Fire . 32
Procedures If Fire Occurs . 34
Precautions for Disposing of Waste Materials 35
Procedures for Exhaust Gas Regulations 36
Precautions for DEF . 37
General Character and Precautions for Handling 37
Precautions for Adding 37
Precautions for Storage . 37
Precautions for Fire Hazard and Leakage . 37
Other Precautions . 37
Store DEF . 38
Precautions When You Handle Hydraulic Equipment . 39
Precautions When You Disconnect and Connect Pipings . 42
Precautions When You Handle Electrical Equipment 49
Precautions When You Handle Fuel System Equipment . 51
Precautions When You Handle Intake System Equipment . 52
Practical Use of KOMTRAX 53
Disconnect and Connect Push-Pull Type Coupler . 54
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 54
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 55
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 56
Precautions for Disconnection and Connection of Connectors 58
How to Disconnect and Connect Deutsch Connector . 62
How to Disconnect and Connect Slide Lock Type Connector . 63
How to Disconnect and Connect Connector with Lock to Pull . 65
How to Disconnect and Connect Connector with Lock to Push . 66
How to Disconnect and Connect Connector with Housing to Rotate 68
How to Read the Codes for Electric Cable 69
Explanation of Terms for Maintenance Standard . 73
Standard Tightening Torque Table 76
Conversion Table 83
Abbreviation List . 88
01 Specifications . 91
Table of Contents . 92
Specifications 93
Specification Drawing . 93
Specification Drawing: D65EX-18 . 93
Specification Drawing: D65PX-18 . 95
Specification Drawing: D65WX-18 . 97
Specifications 99
Specification: D65EX-18 . 99
Specification: D65PX-18 . 106
Specification: D65WX-18 . 112
Weight Table 118
Weight Table: D65EX-18 118
Weight Table: D65PX-18 122
Weight Table: D65WX-18 125
Fuel, Coolant, Lubricant 128
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 128
10 Structure and Function . 131
Table of Contents . 132
Urea SCR System . 135
Layout Drawing of Urea SCR System . 135
Urea SCR System Diagram . 137
Function of Urea SCR System . 138
FUNCTION OF DEF SYSTEM(APPLICABLE MACHINE: 96001 to 96348) 138
FUNCTION OF DEF SYSTEM(APPLICABLE MACHINE: 96349 and up) 140
Inducement Strategy . 143
Component Parts of Urea SCR System 157
DEF Mixing Tube . 157
SCR Assembly 158
DEF Tank 160
DEF Pump 162
DEF Injector 164
DEF Hose 165
DEF Tank Heating Valve 166
Boot-up System 167
Layout Drawing of Boot-up System 167
System Operating Lamp System 169
System Diagram of System Operating Lamp System 169
Function of Operation Lamp System . 169
Battery Disconnect Switch . 171
Layout Drawing of Battery Disconnect Switch . 171
Function of Battery Disconnect Switch . 171
Engine System . 173
Layout Drawing of Engine System . 173
Engine Control System . 175
Layout Drawing of Engine Control System . 175
System Diagram of Engine Control 177
Function of Engine Control System . 179
Automatic Idle Stop System 181
System Diagram of Automatic Idle Stop System 181
Function of Automatic Idle Stop System 181
Component Parts of Engine System 184
Damper 184
VGT . 186
EGR System 190
EGR Valve . 192
EGR Cooler 194
KCCV System . 196
KCCV Ventilator . 198
KDPF 200
Cooling System 204
Layout Drawing of Cooling System 204
Specifications of Cooling System 205
Cooling Fan Control System 206
System Diagram of Cooling Fan Control System 206
Function of Cooling Fan Control System 207
Component Parts of Cooling System . 209
Cooling Fan Pump 209
Cooling Fan Motor . 218
Hydraulic Oil Cooler Bypass Valve . 225
Control System 226
Layout Drawing of Control System 226
Machine Monitor System 227
System Diagram of Machine Monitor System 227
Function of Machine Monitor System 227
KOMTRAX System 229
System Diagram of KOMTRAX System 229
Function of KOMTRAX System 229
Component Parts of Control System . 230
Machine Monitor . 230
Gateway Function Controller . 247
Communication Terminal 250
Power Train Controller 252
Engine Controller . 256
Hydraulic System 263
Layout Drawing of Hydraulic System 263
CLSS 264
Structure of CLSS . 264
Function of CLSS 265
Component Parts of Hydraulic System . 267
Hydraulic Tank 267
Work Equipment and HSS Pump . 269
LS Valve 275
PC Valve 280
PC-EPC Valve 285
Control Valve . 288
Power Train System 319
Layout Drawing of Power Train System 319
Operation of Power Train System . 322
Transmission, Steering, and Brake Control . 323
Layout Drawing of Transmission, Steering, and Brake Control System 323
Function of Transmission, Steering, and Brake Control . 324
Palm Command Control System . 325
Palm Command Control System Diagram . 325
HSS System 329
HSS System Diagram 329
Function of HSS System 330
Centralized Pressure Pickup Port 332
Layout Drawing of Centralized Pressure Pickup Port 332
Function of Centralized Pressure Pickup Port 332
Component Parts of Power Train System . 333
Universal Joint . 333
Power Train Mount . 334
Torque Converter and PTO 335
Lockup Clutch ECMV 341
Transmission 344
Transmission Control Valve 356
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 358
Main Relief Valve and Torque Converter Relief Valve . 363
Transmission Lubrication Relief Valve . 365
Bevel Gear Shaft, HSS, and Brake 366
Brake Valve . 385
Final Drive . 389
Scavenging Pump . 393
Steering Lubrication Pump and Power Train Pump 394
HSS Motor . 395
Electric Steering Electric Lever 401
Work Equipment System . 404
Work Equipment Control 404
Layout Drawing of Work Equipment Control 404
Function of Work Equipment Control 405
Layout Drawing of Tilt Dozer, Power Tilt Pitch Dozer, Angle Dozer and Semi-U Dozer Series . 407
Layout of Power Angle Power Tilt Dozer Series . 409
Layout Drawing of Fixed Multi-Shank Ripper 410
Component Parts of Work Equipment System 411
Self-Pressure Reducing Valve 411
Work Equipment Lock Solenoid Valve 417
Blade PPC Valve . 422
Ripper PPC Valve 428
Blade Pitch Selector Solenoid Valve . 431
Pilot Circuit Accumulator . 432
Angle Control EPC Valve . 433
Quick Drop Valve 436
Piston Valve 438
Undercarriage and Frame . 440
Main Frame 440
Structure of Main Frame . 440
Suspension 442
Structure of Suspension . 442
Specifications of Suspension 443
Function of Suspension 444
Track Frame and Idler Cushion . 445
Structure of Track Frame and Idler Cushion 445
Function of Track Frame and Idler Cushion . 447
Work Equipment 448
Structure of Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series) 448
Structure of Front Work Equipment (For Power Angle Power Tilt Dozer Series) . 449
Structure of Front Work Equipment (Angle Dozer Series) 450
Structure of Fixed Multi-Shank Ripper . 451
CAB Related Parts . 452
ROPS CAB 452
Structure of ROPS CAB . 452
Function of ROPS CAB 453
CAB Mount . 454
Structure of CAB Mount 454
Function of CAB Mount . 454
20 Standard Value Table . 455
Table of Contents . 456
Standard Value Table for Engine . 457
Standard Value Table for Engine: D65EX-18 . 457
Standard Value Table for Engine: D65PX-18 . 462
Standard Value Table for Engine: D65WX-18 . 467
Standard Value Table for Machine 472
Standard Value Table for Machine: D65EX-18 472
Standard Value Table for Machine: D65PX-18 487
Standard Value Table for Machine: D65WX-18 502
Machine Posture and Procedures to Measure Performance . 516
30 Testing and Adjusting 519
Table of Contents . 520
Precautions Before Work . 523
Related Information on Testing and Adjusting 524
Differences In Machine Monitor Symbols 524
Tools for Testing and Adjusting . 525
Sketch of Tools for Testing and Adjusting . 531
Engine and Cooling System . 532
Examine Engine Speed 532
How to Examine Engine Speed . 532
Examine Boost Pressure 536
How to Examine Boost Pressure . 536
Examine Exhaust Gas Temperature . 538
How to Examine Exhaust Gas Temperature 538
Examine Exhaust Gas Color . 540
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 540
How to Examine Exhaust Gas Color with Smoke Meter . 540
Examine Mass Air Flow and Temperature Sensor 542
How to Examine Mass Air Flow and Temperature Sensor . 542
Examine and Adjust Valve Clearance 544
How to Examine Valve Clearance 544
How to Adjust Valve Clearance . 545
Examine Compression Pressure 547
How to Examine Compression Pressure . 547
Examine Blowby Pressure . 549
How to Examine Blowby Pressure 549
Examine Engine Oil Pressure . 552
How to Examine Engine Oil Pressure 552
Examine EGR Valve and VGT Oil Pressure 553
How to Examine EGR Valve and VGT Oil Pressure . 553
Examine Fuel Pressure . 555
How to Examine Fuel Pressure 556
Examine Fuel Discharge, Return and Leakage 562
How to Examine Fuel Discharge, Return, and Leakage 563
Bleed Air from Fuel System 567
How to Bleed Air from Fuel System . 567
Examine Fuel Circuit for Leakage 569
How to Examine Fuel System for Leakage 569
Handle Cylinder Cut-out Mode Operation 571
Handle No-Injection Cranking Operation 572
Examine and Adjust Air Conditioner Compressor Belt Tension 573
How to Examine Air Conditioner Compressor Belt Tension 573
How to Adjust Air Conditioner Compressor Belt Tension . 573
Examine Alternator Belt . 574
How to Examine Alternator Belt 574
Examine Automatic Tensioner . 576
How to Examine Automatic Tensioner 576
Write Correction for Ash in Soot Accumulation to Engine Controller 578
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 578
Examine SCR Related Functions . 579
Examine DEF Pump Raised Pressure 583
Examine Injection Volume from DEF Injector 586
Examine DEF Line Heater Relay 1 . 591
Examine DEF Line Heater Relay 2 . 594
Examine DEF Pump Heater Relay . 597
Examine DEF Tank Heater Valve . 600
Examine SCR Denitration Efficiency 603
Clean DEF Tank 606
How to Clean DEF Tank . 606
Clean DEF Tank Mounting Part 610
How to Clean DEF Tank Mounting Part . 610
Clean DEF Pump 612
How to Clean DEF Pump . 612
Adjust Decelerator Pedal 618
How to Adjust Decelerator Pedal . 618
Power Train . 620
Examine Power Train Oil Pressure 620
How to Examine Power Train Oil Pressure . 621
Adjust Transmission Output Shaft Speed Sensor . 632
How to Adjust Transmission Output Shaft Speed Sensor 632
Examine Brake Performance Simply 634
How to Examine Brake Performance Simply . 634
Adjust Brake Pedal 635
How to Adjust Brake Pedal . 635
Adjust Parking Brake Lever 637
How to Adjust Parking Brake Lever . 637
Move Machine by Parking Brake Release When Machine Does Not Travel 639
How to Move Machine with Hydraulic Type Parking Brake Release System 639
How to Move Machine with Electric Type Parking Brake Release System . 640
Undercarriage and Frame . 642
Adjust Idler Clearance 642
How to Adjust Idler Clearance . 642
Examine and Adjust Track Tension 643
How to Examine Track Tension 643
How to Adjust Track Tension . 643
Hydraulic System 644
Release Remained Pressure in Hydraulic Circuit 644
How to Release Remained Pressure in Hydraulic System 644
Examine and Adjust Work Equipment and HSS Oil Pressure 645
How to Examine Work Equipment and HSS Oil Pressure 645
How to Adjust Oil Pressure of Work Equipment and HSS 649
Examine Oil Pressure of Control Circuit . 650
How to Examine Oil Pressure in Control Circuit 650
Examine PPC Valve Outlet Pressure . 652
How to Examine Outlet Pressure in PPC Valve . 652
Bleed Air from HSS Pump . 654
How to Bleed Air from HSS Pump 654
Examine and Adjust Play of Work Equipment PPC Valve . 655
How to Examine Play of Work Equipment PPC Valve . 655
How to Adjust Play of Work Equipment PPC Valve 656
Examine Cooling Fan Speed . 657
How to Examine Cooling Fan Speed 657
Examine Cooling Fan Circuit Oil Pressure 658
How to Examine Cooling Fan Circuit Oil Pressure . 658
Bleed Air in Cooling Fan Pump . 660
How to Bleed Air in Cooling Fan Pump 660
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 661
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder . 661
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder . 661
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 662
Examine Oil Leakage from Work Equipment Cylinder 663
How to Examine Internal Oil Leakage of Work Equipment Cylinder 663
Bleed Air from Work Equipment Cylinders . 665
How to Bleed Air from Work Equipment Cylinder . 665
Work Equipment 667
Adjust Work Equipment Lock Lever 667
How to Adjust Work Equipment Lock Lever . 667
CAB Related Parts . 669
Examine and Adjust Operator Cab . 669
How to Examine Operator Cab . 669
How to Adjust Operator Cab 671
Electrical System . 674
Set and Operate Machine Monitor . 674
Operator Mode . 678
Function to Show Technician Identification Status Screen 678
Function to Show Operator Identification Input Screen . 678
Examine Function by LCD (Liquid Crystal Display) 679
Examine Function of Service Meter . 679
How to Set Usage Limitation and Change Maintenance Password . 679
Service Mode 682
How to Operate Service Mode . 682
How to See Pre-defined Monitoring Information . 683
How to Examine Monitoring Information . 689
Abnormality Record Menu . 700
How to See Maintenance Record . 704
Maintenance Mode Setting 705
How to Set Phone Number Entry . 709
Default Setting Menu 711
Testing Menu 720
Adjustment Menu . 729
No-Injection Cranking Operation . 756
KOMTRAX Settings Menu . 759
How to Show Service Message . 761
How to Start Up KOMTRAX System 763
How to Stop Use of KOMTRAX System . 768
Adjust When Power Train Controller is Replaced 770
How to Adjust When Power Train Controller is Replaced . 770
Adjust Rearview Camera Angle 773
How to Adjust Rearview Camera Angle . 773
Set Region of Bluetooth(R) Compatible Radio . 774
How to Set Region of Bluetooth(R) Compatible Radio 774
Handle Voltage Circuit of Engine Controller . 776
Handle Battery Disconnect Switch 777
Examine Diodes 778
How to Examine Diodes by Digital Tester . 778
How to Examine Diodes by Analog Tester 778
Pm Clinic . 779
Pm Clinic Service . 779
Pm Clinic Check Sheet: D65EX-18 . 781
Pm Clinic Check Sheet: D65PX-18 . 793
Pm Clinic Check Sheet: D65WX-18 . 805
Pm Clinic Check Sheet for Undercarriage: D65EX-18 . 817
Pm Clinic Check Sheet for Undercarriage: D65PX-18 . 824
Pm Clinic Check Sheet for Undercarriage: D65WX-18 . 830
40 Troubleshooting 837
Table of Contents . 838
Precautions Before Work . 848
Related Information to Troubleshooting 849
General Troubleshooting Points 849
Troubleshooting Points for Urea SCR System 850
Sequence of Events in Troubleshooting . 864
Checks Before Troubleshooting . 866
Inspection Procedure Before Troubleshooting . 868
Walk-Around Check . 868
Test in Accordance with Testing Procedure . 870
How to Examine Electric Equipment . 870
Preparation for Troubleshooting of Electrical System 878
Procedure for Troubleshooting . 885
Symptom and Troubleshooting Numbers . 888
Information Shown in Troubleshooting Table 891
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness . 893
Connector List and Layout . 895
Connector Contact Connection Table 915
T-Branch Box and T-Branch Adapter Table . 955
Fuse Location Table . 961
Precautions When You Clean and Replace KDPF (KCSF and KDOC) . 964
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 968
Failure Code Table 970
Troubleshooting by Failure Code (Display of Code) . 989
Failure Code [1500L0] . 989
Failure Code [15SAL1] . 990
Failure Code [15SALH] . 992
Failure Code [15SBL1] . 994
Failure Code [15SBLH] . 996
Failure Code [15SEL1] . 998
Failure Code [15SELH] .1000
Failure Code [15SFL1] .1002
Failure Code [15SFLH] .1004
Failure Code [15SGL1] .1006
Failure Code [15SGLH] .1008
Failure Code [15SJL1] .1010
Failure Code [15SJLH] .1012
Failure Code [1800MW] .1014
Failure Code [879AKA] .1015
Failure Code [879AKB] .1016
Failure Code [879BKA] .1017
Failure Code [879BKB] .1019
Failure Code [879CKA] .1021
Failure Code [879CKB] .1022
Failure Code [879DKZ] .1023
Failure Code [879EMC] .1025
Failure Code [879FMC] .1026
Failure Code [879GKX] .1027
Failure Code [989L00] .1029
Failure Code [989M00] .1030
Failure Code [989N00] .1031
Failure Code [A1U0N3] .1032
Failure Code [A1U0N4] .1034
Failure Code [A900FR] .1036
Failure Code [A900N6] .1037
Failure Code [A900NY] .1038
Failure Code [AA10NX] .1039
Failure Code [AB00KE] .1041
Failure Code [AQ10N3] .1043
Failure Code [AS00N3] .1045
Failure Code [AS00R2] .1047
Failure Code [AS00R3] .1048
Failure Code [AS00R4] .1049
Failure Code [AS00R5] .1050
Failure Code [AS00R6] .1051
Failure Code [AS00ZK] .1052
Failure Code [AS10KM] .1053
Failure Code [AS10NR] .1054
Failure Code [AS10NT] .1055
Failure Code [B@BAZG] .1056
Failure Code [B@BCNS] .1057
Failure Code [B@BCQA] .1058
Failure Code [B@BCZK] .1060
Failure Code [B@CENS] .1062
Failure Code [B@HANS] .1063
Failure Code [CA115] 1064
Failure Code [CA122] 1065
Failure Code [CA123] 1067
Failure Code [CA131] 1069
Failure Code [CA132] 1071
Failure Code [CA144] 1074
Failure Code [CA145] 1076
Failure Code [CA153] 1078
Failure Code [CA154] 1081
Failure Code [CA187] 1084
Failure Code [CA221] 1086
Failure Code [CA222] 1088
Failure Code [CA227] 1090
Failure Code [CA234] 1091
Failure Code [CA238] 1092
Failure Code [CA239] 1094
Failure Code [CA249] 1096
Failure Code [CA256] 1098
Failure Code [CA271] 1100
Failure Code [CA272] 1102
Failure Code [CA281] 1104
Failure Code [CA322] 1105
Failure Code [CA323] 1107
Failure Code [CA324] 1109
Failure Code [CA325] 1111
Failure Code [CA331] 1113
Failure Code [CA332] 1115
Failure Code [CA343] 1117
Failure Code [CA351] 1118
Failure Code [CA352] 1119
Failure Code [CA356] 1122
Failure Code [CA357] 1124
Failure Code [CA386] 1126
Failure Code [CA428] 1127
Failure Code [CA429] 1129
Failure Code [CA435] 1131
Failure Code [CA441] 1133
Failure Code [CA442] 1135
Failure Code [CA449] 1136
Failure Code [CA451] 1140
Failure Code [CA452] 1143
Failure Code [CA515] 1145
Failure Code [CA516] 1147
Failure Code [CA553] 1149
Failure Code [CA555] 1150
Failure Code [CA556] 1151
Failure Code [CA559] 1152
Failure Code [CA595] 1156
Failure Code [CA687] 1157
Failure Code [CA689] 1159
Failure Code [CA691] 1164
Failure Code [CA692] 1166
Failure Code [CA697] 1168
Failure Code [CA698] 1169
Failure Code [CA731] 1170
Failure Code [CA778] 1172
Failure Code [CA1117] .1177
Failure Code [CA1664] .1178
Failure Code [CA1669] .1181
Failure Code [CA1673] .1182
Failure Code [CA1677] .1183
Failure Code [CA1678] .1184
Failure Code [CA1682] .1185
Failure Code [CA1683] .1190
Failure Code [CA1684] .1192
Failure Code [CA1686] .1194
Failure Code [CA1691] .1195
Failure Code [CA1694] .1198
Failure Code [CA1695] .1201
Failure Code [CA1696] .1202
Failure Code [CA1712] .1204
Failure Code [CA1713] .1207
Failure Code [CA1714] .1209
Failure Code [CA1715] .1210
Failure Code [CA1776] .1211
Failure Code [CA1777] .1214
Failure Code [CA1843] .1217
Failure Code [CA1844] .1219
Failure Code [CA1879] .1222
Failure Code [CA1881] .1225
Failure Code [CA1883] .1228
Failure Code [CA1885] .1232
Failure Code [CA1887] .1234
Failure Code [CA1921] .1236
Failure Code [CA1922] .1239
Failure Code [CA1942] .1244
Failure Code [CA1993] .1245
Failure Code [CA2185] .1248
Failure Code [CA2186] .1250
Failure Code [CA2249] .1252
Failure Code [CA2265] .1253
Failure Code [CA2266] .1255
Failure Code [CA2271] .1257
Failure Code [CA2272] .1260
Failure Code [CA2311] .1263
Failure Code [CA2349] .1264
Failure Code [CA2353] .1267
Failure Code [CA2357] .1269
Failure Code [CA2381] .1270
Failure Code [CA2382] .1273
Failure Code [CA2383] .1276
Failure Code [CA2386] .1279
Failure Code [CA2387] .1281
Troubleshooting Flowchart .1285
Failure Code [CA2555] .1286
Failure Code [CA2556] .1289
Failure Code [CA2637] .1292
Failure Code [CA2639] .1294
Failure Code [CA2771] .1297
Failure Code [CA2777] .1303
Failure Code [CA2976] .1306
Failure Code [CA3133] .1308
Failure Code [CA3134] .1310
Failure Code [CA3135] .1312
Failure Code [CA3142] .1316
Failure Code [CA3143] .1317
Failure Code [CA3144] .1318
Failure Code [CA3146] .1320
Failure Code [CA3147] .1321
Failure Code [CA3148] .1322
Failure Code [CA3151] .1324
Failure Code [CA3165] .1330
Failure Code [CA3229] .1332
Failure Code [CA3231] .1334
Failure Code [CA3232] .1336
Failure Code [CA3235] .1340
Failure Code [CA3239] .1342
Failure Code [CA3241] .1345
Failure Code [CA3242] .1348
Failure Code [CA3251] .1351
Failure Code [CA3253] .1353
Failure Code [CA3254] .1356
Failure Code [CA3255] .1359
Failure Code [CA3256] .1362
Failure Code [CA3311] .1364
Failure Code [CA3312] .1366
Failure Code [CA3313] .1369
Failure Code [CA3314] .1370
Failure Code [CA3315] .1371
Failure Code [CA3316] .1374
Failure Code [CA3317] .1375
Failure Code [CA3318] .1376
Failure Code [CA3319] .1379
Failure Code [CA3321] .1380
Failure Code [CA3322] .1382
Failure Code [CA3419] .1385
Failure Code [CA3421] .1387
Failure Code [CA3497] .1389
Failure Code [CA3498] .1390
Failure Code [CA3543] .1391
Failure Code [CA3545] .1398
Failure Code [CA3547] .1400
Failure Code [CA3558] .1401
Failure Code [CA3559] .1403
Failure Code [CA3562] .1405
Failure Code [CA3563] .1407
Failure Code [CA3567] .1410
Failure Code [CA3568] .1413
Failure Code [CA3571] .1419
Failure Code [CA3572] .1421
Failure Code [CA3574] .1423
Failure Code [CA3575] .1426
Failure Code [CA3577] .1428
Failure Code [CA3578] .1430
Failure Code [CA3582] .1432
Failure Code [CA3583] .1441
Failure Code [CA3596] .1443
Failure Code [CA3649] .1446
Failure Code [CA3681] .1448
Failure Code [CA3682] .1450
Failure Code [CA3713] .1453
Failure Code [CA3717] .1456
Failure Code [CA3718] .1457
Failure Code [CA3725] .1458
Failure Code [CA3741] .1461
Failure Code [CA3748] .1462
Failure Code [CA3751] .1465
Failure Code [CA3755] .1467
Failure Code [CA3866] .1469
Failure Code [CA3867] .1473
Failure Code [CA3868] .1476
Failure Code [CA3899] .1480
Failure Code [CA3911] .1482
Failure Code [CA3912] .1486
Failure Code [CA3932] .1488
Failure Code [CA3933] .1490
Failure Code [CA3934] .1492
Failure Code [CA3935] .1495
Failure Code [CA3936] .1497
Failure Code [CA4151] .1499
Failure Code [CA4152] .1503
Failure Code [CA4155] .1507
Failure Code [CA4156] .1510
Failure Code [CA4157] .1513
Failure Code [CA4158] .1515
Failure Code [CA4159] .1516
Failure Code [CA4161] .1517
Failure Code [CA4162] .1520
Failure Code [CA4163] .1523
Failure Code [CA4164] .1525
Failure Code [CA4165] .1527
Failure Code [CA4166] .1529
Failure Code [CA4168] .1531
Failure Code [CA4169] .1534
Failure Code [CA4171] .1536
Failure Code [CA4249] .1539
Failure Code [CA4251] .1541
Failure Code [CA4259] .1543
Failure Code [CA4261] .1546
Failure Code [CA4277] .1549
Failure Code [CA4281] .1553
Failure Code [CA4459] .1557
Failure Code [CA4461] .1560
Failure Code [CA4658] .1563
Failure Code [CA4731] .1567
Failure Code [CA4732] .1568
Failure Code [CA4739] .1569
Failure Code [CA4768] .1570
Failure Code [CA4769] .1572
Failure Code [CA4842] .1575
Failure Code [CA4952] .1579
Failure Code [CA5115] .1581
Failure Code [CA5383] .1584
Failure Code [D130KA] .1586
Failure Code [D130KB] .1589
Failure Code [D19JKZ] .1591
Failure Code [D19UKA] .1594
Failure Code [D19UKB] .1596
Failure Code [D19UMC] .1598
Failure Code [D811MC] .1600
Failure Code [D862KA] .1601
Failure Code [D8ALKA] .1602
Failure Code [D8ALKB] .1604
Failure Code [D8AQKR] .1607
Failure Code [D8ARKR] .1609
Failure Code [D8G1KT] .1612
Failure Code [D8G6KT] .1613
Failure Code [DAF0MB] .1614
Failure Code [DAF0MC] .1615
Failure Code [DAF8KB] .1616
Failure Code [DAF9KQ] .1617
Failure Code [DAFGMC] .1618
Failure Code [DAFLKA] .1619
Failure Code [DAFLKB] .1621
Failure Code [DAFQKR] .1624
Failure Code [DAQW00] .1625
Failure Code [DAZ9KQ] .1626
Failure Code [DAZQKR] .1627
Failure Code [DB2QKR] .1628
Failure Code [DB2RKR] .1636
Failure Code [DBE0KT] .1642
Failure Code [DBE0MC] .1643
Failure Code [DBE1KK] .1644
Failure Code [DBE2KK] .1647
Failure Code [DBE2KT] .1650
Failure Code [DBE5KK] .1651
Failure Code [DBE6KK] .1653
Failure Code [DBE7KK] .1655
Failure Code [DBE9KQ] .1657
Failure Code [DBELKA] .1658
Failure Code [DBELKB] .1660
Failure Code [DBEQKR] .1662
Failure Code [DBERKR] .1663
Failure Code [DD12KA] .1666
Failure Code [DD12KB] .1668
Failure Code [DD13KA] .1670
Failure Code [DD13KB] .1672
Failure Code [DD14KA] .1674
Failure Code [DD14KB] .1676
Failure Code [DDKHKA] .1678
Failure Code [DDKHKB] .1680
Failure Code [DDN7KA] .1682
Failure Code [DDN7KB] .1684
Failure Code [DDNLKA] .1686
Failure Code [DDNLKB] .1688
Failure Code [DGS1KA] .1690
Failure Code [DGS1KX] .1692
Failure Code [DGT1KA] .1694
Failure Code [DGT1KX] .1697
Failure Code [DH21KA] .1699
Failure Code [DH21KY] .1701
Failure Code [DHA4KA] .1703
Failure Code [DHAAMA] .1705
Failure Code [DHACMA] .1707
Failure Code [DHTDKA] .1709
Failure Code [DHTDKY] .1711
Failure Code [DK10KA] .1713
Failure Code [DK10KB] .1716
Failure Code [DK30KA] .1718
Failure Code [DK30KX] .1721
Failure Code [DK30KY] .1722
Failure Code [DK30KZ] .1724
Failure Code [DK30L8] .1725
Failure Code [DK31KA] .1726
Failure Code [DK31KY] .1729
Failure Code [DK40KA] .1731
Failure Code [DK40KY] .1733
Failure Code [DK55KX] .1735
Failure Code [DK55KZ] .1736
Failure Code [DK55L8] .1737
Failure Code [DK56KA] .1738
Failure Code [DK56KY] .1740
Failure Code [DK57KA] .1742
Failure Code [DK57KY] .1744
Failure Code [DKH1KA] .1746
Failure Code [DKH1KY] .1749
Failure Code [DLM3KA] .1751
Failure Code [DLM3MB] .1753
Failure Code [DLT3KA] .1754
Failure Code [DLT3KB] .1756
Failure Code [DR21KX] .1758
Failure Code [DR31KX] .1759
Failure Code [DV20KB] .1760
Failure Code [DW5AKA] .1762
Failure Code [DW5AKB] .1764
Failure Code [DW5AKY] .1766
Failure Code [DW7BKA] .1768
Failure Code [DW7BKB] .1770
Failure Code [DW7BKY] .1772
Failure Code [DWN1KA] (Applicable Machine: 96001 to 96603) 1773
Failure Code [DWN1KA] (Applicable Machine: 96604 and Up) 1775
Failure Code [DWN1KB] (Applicable Machine: 96001 to 96603) 1777
Failure Code [DWN1KB] (Applicable Machine: 96604 and Up) 1779
Failure Code [DWN1KY] (Applicable Machine: 96001 to 96603) 1781
Failure Code [DWN1KY] (Applicable Machine: 96604 and Up) 1783
Failure Code [DWN2KA] (Applicable Machine: 96001 to 96603) 1785
Failure Code [DWN2KA] (Applicable Machine: 96604 and Up) 1787
Failure Code [DWN2KB] (Applicable Machine: 96001 to 96603) 1789
Failure Code [DWN2KB] (Applicable Machine: 96604 and Up) 1791
Failure Code [DWN2KY] (Applicable Machine: 96001 to 96603) 1793
Failure Code [DWN2KY] (Applicable Machine: 96604 and Up) 1794
Failure Code [DWN5KA] .1796
Failure Code [DWN5KB] .1798
Failure Code [DWN5KY] .1799
Failure Code [DXA2KA] .1801
Failure Code [DXA2KB] .1803
Failure Code [DXA2KY] .1805
Failure Code [DXH1KA] .1806
Failure Code [DXH1KB] .1808
Failure Code [DXH1KY] .1810
Failure Code [DXH4KA] .1812
Failure Code [DXH4KB] .1814
Failure Code [DXH4KY] .1816
Failure Code [DXH5KA] .1818
Failure Code [DXH5KB] .1820
Failure Code [DXH5KY] .1822
Failure Code [DXH6KA] .1824
Failure Code [DXH6KB] .1826
Failure Code [DXH6KY] .1828
Failure Code [DXH7KA] .1830
Failure Code [DXH7KB] .1832
Failure Code [DXH7KY] .1834
Failure Code [DXH8KA] .1836
Failure Code [DXH8KB] .1838
Failure Code [DXH8KY] .1840
Failure Code [DXJ4KA] .1842
Failure Code [DXJ4KB] .1844
Failure Code [F311KA] .1846
Failure Code [F311KB] .1848
Failure Code [F312KA] .1850
Failure Code [F312KB] .1852
Failure Code [F313KA] .1854
Failure Code [F313KB] .1856
Failure Code [F314KA] .1859
Failure Code [F314KB] .1861
Failure Code [F315KB] .1863
Failure Code [F315KY] .1865
Failure Code [F316KB] .1867
Failure Code [F316KY] .1869
Failure Code [F318KB] .1871
Failure Code [F318KY] .1874
Failure Code [F31AKB] .1876
Failure Code [F31AKY] .1878
Failure Code [F31BKB] .1880
Failure Code [F31BKY] .1882
Failure Code [F31CKB] .1884
Failure Code [F31CKY] .1886
Failure Code [F31DKB] .1888
Failure Code [F31DKY] .1890
Failure Code [F31EKB] .1892
Failure Code [F31EKY] .1894
Failure Code [FS10ZE] .1896
Troubleshooting of Electrical System (E-Mode) .1897
Engine Does Not Start (Engine Does Not Crank) .1897
Manual Preheating System Does Not Operate .1904
Automatic Preheating System Does Not Operate 1907
While Preheating is in Operation, Preheating Monitor Does Not Come On .1909
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1911
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On .1915
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1916
Charge Level Monitor Comes On in Red While Engine is in Operation .1917
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .1919
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1920
Power Train Oil Temperature Monitor Comes On in Red While Engine Runs .1921
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1922
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1923
DEF Level is Not Shown Correctly 1924
Fuel Gauge Does Not Show Normally .1927
Power Train Oil Temperature Gauge Does Not Show Correct Temperature .1929
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature .1930
Operation Mode Does Not Change 1931
Gear Shift Mode Does Not Change .1932
When You Operate Customize Switch Does Not Show Customize Screen 1933
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 1934
Some Areas of Machine Monitor Screen are Not Shown 1935
REVERSE Slow Mode Function Does Not Operate Correctly .1936
Alarm Buzzer Does Not Operate or Does Not Stop Operation 1937
Service Meter is Not Shown While Starting Switch is in OFF Position .1938
Service Mode Cannot be Selected .1939
Horn Does Not Sound .1940
Horn Does Not Stop 1942
Backup Alarm Does Not Sound .1943
Backup Alarm Does Not Stop Operation 1945
Headlamp Does Not Come On .1946
Rear Lamp Does Not Come On 1950
No Wiper Operates .1953
Front Wiper Does Not Operate 1957
Rear Wiper Does Not Operate .1960
Left Door Wiper Does Not Operate 1963
Right Door Wiper Does Not Operate .1966
Front Washer Does Not Operate .1969
Rear Washer Does Not Operate 1971
Left Door Washer Does Not Operate .1973
Right Door Washer Does Not Operate 1975
KOMTRAX System Does Not Operate Correctly .1977
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .1978
Information Shown in Troubleshooting Table (H-Mode) .1978
System Chart of Hydraulic and Mechanical Systems 1979
Failure Mode and Cause Table 1981
Machine Lacks Power (Drawbar Pull is Not Sufficient) 1989
Machine Does Not Travel (at 2nd or 3rd Gear Speed) 1991
Machine Does Not Move Off at All Gear Speeds 1992
Machine Travels Only in One Direction, Forward or in Reverse 1994
Large Time Lag is in Gear Shifting or Directional Change 1995
Brake Does Not Work .1997
Power Train Oil Overheats .1998
Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor .2000
Torque Converter Lockup Clutch Does Not Engage 2001
Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) .2002
Steering Speed or Power is Not Sufficient .2003
All Work Equipment Operate Slowly .2004
All Work Equipment Do Not Operate .2005
Blade Lift Speed or Power is Low 2006
Blade Tilt Speed or Power is Low 2007
Blade Angle Speed or Power is Low .2008
Ripper Lift Speed or Power is Low .2009
Hydraulic Drift of Blade Lift is Large 2010
Hydraulic Drift of Tilted Blade is Large 2011
Hydraulic Drift of Lifted Ripper is Large .2012
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2013
Unusual Noise is Heard from Around Fan 2015
Troubleshooting of Engine (S-Mode) 2016
Information Shown in Troubleshooting Table (S-Mode) .2016
Engine Does Not Crank When Starting Switch is Turned to Start Position 2017
Engine Cranks but No Exhaust Smoke Comes Out 2018
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2019
Engine Startability is Unsatisfactory .2021
Engine Does Not Pick Up Smoothly 2023
Engine Stops During Operation .2025
Engine Does Not Rotate Smoothly .2027
Engine Lacks Output (or Lacks Power) 2028
KDPF Becomes Clogged in a Short Time 2030
Engine Oil Consumption is Excessive .2032
Engine Oil Becomes Dirty Quickly 2033
Fuel Consumption is Excessive .2034
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2035
Engine Oil Pressure Drops .2036
Fuel Mixes Into Engine Oil 2038
Water Mixes Into Engine Oil (Milky) .2039
Coolant Temperature Increases Too High (Overheat) .2040
Unusual Noise is Heard 2041
Vibration is Excessive 2042
Air Cannot be Bled from Fuel Circuit 2043
Active Regeneration is Done Frequently 2044
Active Regeneration Continues Long 2046
White Smoke is Exhausted During Active Regeneration .2047
DEF Consumption is Excessive 2048
There is an Unusual Smell (Irritating Odor) .2050
Foreign Materials Enter DEF (DEF Increases) .2051
50 Disassembly and Assembly .2053
Table of Contents .2054
Precautions Before Work .2059
Related Information on Disassembly and Assembly .2060
How to Read This Manual .2060
Coating Materials List 2061
Special Tool List .2066
Sketches of Special Tools .2088
Engine and Cooling System .2109
Remove and Install Supply Pump Assembly .2109
How to Remove Supply Pump Assembly 2109
How to Install Supply Pump Assembly .2113
Remove and Install Injector Assembly 2118
How to Remove Injector Assembly .2119
How to Install Injector Assembly 2126
Remove and Install Cylinder Head Assembly .2137
How to Remove Cylinder Head Assembly 2138
How to Install Cylinder Head Assembly .2148
Remove and Install EGR Valve Assembly .2164
How to Remove EGR Valve Assembly 2164
How to Install EGR Valve Assembly .2165
Remove and Install EGR Cooler Assembly 2166
How to Remove EGR Cooler Assembly .2166
How to Install EGR Cooler Assembly 2167
Remove and Install Starter Assembly .2169
How to Remove Starting Motor Assembly .2169
How to Install Starting Motor Assembly 2171
Remove and Install Alternator Belt 2174
How to Remove Alternator Belt .2174
How to Install Alternator Belt 2175
Remove and Install Automatic Tensioner 2177
How to Remove Automatic Tensioner .2177
How to Install Automatic Tensioner 2177
Remove and Install Expansion Tank Assembly 2178
How to Remove Expansion Tank Assembly .2178
How to Install Expansion Tank Assembly 2182
Remove and Install Radiator Assembly 2187
How to Remove Radiator Assembly .2187
How to Install Radiator Assembly 2190
Remove and Install Hydraulic Oil Cooler Assembly 2194
How to Remove Hydraulic Oil Cooler Assembly .2194
How to Install Hydraulic Oil Cooler Assembly 2196
Remove and Install Aftercooler Assembly .2200
How to Remove Aftercooler Assembly 2200
How to Install Aftercooler Assembly .2202
Remove and Install Power Train Oil Cooler Assembly 2205
How to Remove Power Train Oil Cooler Assembly .2205
How to Install Power Train Oil Cooler Assembly 2207
Remove and Install Cooling Fan Drive Assembly .2210
How to Remove Cooling Fan Drive Assembly 2210
How to Install Cooling Fan Drive Assembly .2211
Remove and Install Cooling Fan Motor Assembly .2214
How to Remove Cooling Fan Motor Assembly 2214
How to Install Cooling Fan Motor Assembly .2216
Remove and Install Engine Assembly 2218
How to Remove Engine Assembly .2218
How to Install Engine Assembly 2223
Remove and Install Engine Front Oil Seal 2229
How to Remove Engine Front Oil Seal .2229
How to Install Engine Front Oil Seal 2231
Remove and Install Engine Rear Oil Seal .2235
How to Remove Engine Rear Oil Seal 2235
How to Install Engine Rear Oil Seal .2239
Remove and Install Engine Hood Assembly .2247
How to Remove Engine Hood Assembly 2247
How to Install Engine Hood Assembly .2251
Remove and Install Fuel Tank Assembly .2255
How to Remove Fuel Tank Assembly 2255
How to Install Fuel Tank Assembly .2258
Remove and Install DEF Tank Assembly 2261
How to Remove DEF Tank Assembly .2262
How to Install DEF Tank Assembly 2266
Remove and Install DEF Tank Sensor Flange Assembly 2270
How to Remove DEF Tank Sensor Flange Assembly .2271
How to Install DEF Tank Sensor Flange Assembly 2275
Remove and Install DEF Tank Sensor 2282
How to Remove DEF Tank Sensor .2282
How to Install DEF Tank Sensor 2283
Remove and Install DEF Tank Strainer 2290
How to Remove DEF Tank Strainer .2290
How to Install DEF Tank Strainer 2290
Remove and Install KDPF Assembly 2291
How to Remove KDPF Assembly .2291
How to Install KDPF Assembly 2295
Disassemble and Assemble KDPF Assembly 2299
How to Disassemble KDPF Assembly 2299
How to Assemble KDPF Assembly .2303
Remove and Install SCR Assembly .2309
How to Remove SCR Assembly 2309
How to Install SCR Assembly .2311
Remove and Install KDPF and SCR Assembly 2314
How to Remove KDPF and SCR Assembly .2314
How to Install KDPF and SCR Assembly 2321
Remove and Install KCCV Assembly 2328
How to Remove KCCV Assembly .2328
How to Install KCCV Assembly 2330
Remove and Install DEF Mixing Tube 2332
How to Remove DEF Mixing Tube .2332
How to Install DEF Mixing Tube 2335
Remove and Install DEF Injector .2340
How to Remove DEF Injector 2340
How to Install DEF Injector .2343
Remove and Install DEF Pump .2347
How to Remove DEF Pump 2347
How to Install DEF Pump .2350
Remove and Install DEF Hose .2353
How to Remove DEF Hose 2353
How to Install DEF Hose .2358
Remove and Install Air Cleaner Assembly .2363
How to Remove Air Cleaner Assembly 2363
How to Install Air Cleaner Assembly .2364
Remove and Install Air Conditioner Compressor Assembly 2366
How to Remove Air Conditioner Compressor Assembly .2366
How to Install Air Conditioner Compressor Assembly 2368
Remove and Install Air Conditioner Condenser Assembly .2371
How to Remove Air Conditioner Condenser Assembly 2371
How to Install Air Conditioner Condenser Assembly .2373
Power Train .2375
Remove and Install Damper Assembly 2375
How to Remove Damper Assembly .2375
How to Install Damper Assembly 2378
Remove and Install Power Train Unit Assembly 2383
How to Remove Power Train Unit Assembly .2383
How to Install Power Train Unit Assembly 2388
Disconnect and Connect Power Train Unit Assembly 2394
How to Disconnect Power Train Unit Assembly .2394
How to Connect Power Train Unit Assembly 2399
Disassemble and Assemble PTO Assembly .2405
How to Disassemble PTO Assembly .2405
How to Assemble PTO Assembly 2408
Disassemble and Assemble Torque Converter Assembly 2412
How to Disassemble Torque Converter Assembly 2413
How to Assemble Torque Converter Assembly .2419
Disassemble and Assemble Transmission Assembly 2428
How to Disassemble Transmission Assembly 2429
How to Assemble Transmission Assembly .2447
Disassemble and Assemble HSS Assembly .2460
How to Disassemble HSS Assembly .2462
How to Assemble HSS Assembly 2473
Remove and Install HSS Motor Assembly .2490
How to Remove HSS Motor Assembly 2490
How to Install HSS Motor Assembly .2492
Remove and Install Final Drive Assembly .2495
How to Remove Final Drive Assembly 2495
How to Install Final Drive Assembly .2498
Disassemble and Assemble Final Drive Assembly .2501
How to Disassemble Final Drive Assembly .2502
How to Assemble Final Drive Assembly 2507
Undercarriage and Frame .2515
Remove and Install Track Frame Assembly .2515
How to Remove Track Frame Assembly 2515
How to Install Track Frame Assembly .2518
Remove and Install Idler Assembly .2522
How to Remove Idler Assembly 2522
How to Install Idler Assembly .2523
Disassemble and Assemble Idler Assembly .2525
How to Disassemble Idler Assembly .2525
How to Assemble Idler Assembly 2527
Remove and Install Recoil Spring Assembly .2531
How to Remove Recoil Spring Assembly 2531
How to Install Recoil Spring Assembly .2531
Disassemble and Assemble Recoil Spring Assembly .2533
How to Disassemble Recoil Spring Assembly .2533
How to Assemble Recoil Spring Assembly 2536
Remove and Install Track Roller Assembly 2539
How to Remove Track Roller Assembly .2539
How to Install Track Roller Assembly 2540
Disassemble and Assemble Track Roller Assembly 2541
How to Disassemble Track Roller Assembly 2541
How to Assemble Track Roller Assembly .2543
Remove and Install Carrier Roller Assembly 2546
How to Remove Carrier Roller Assembly .2546
How to Install Carrier Roller Assembly 2547
Disassemble and Assemble Carrier Roller Assembly 2548
How to Disassemble Carrier Roller Assembly 2548
How to Assemble Carrier Roller Assembly .2549
Remove and Install Pivot Shaft Assembly .2552
How to Remove Pivot Shaft Assembly 2552
How to Install Pivot Shaft Assembly .2553
Separate and Connect Track Assembly .2554
How to Examine Before Separation of Track Assembly 2554
How to Separate Track Assembly (Standard) .2554
How to Separate Track Assembly (When Track Frame Has Internal Defect) .2555
How to Install Track Assembly .2556
Separate and Connect PLUS Type Track Assembly .2559
Separate PLUS Type Track Assembly Generally .2559
Install PLUS Type Track Assembly 2559
Disassemble and Assemble Track Assembly Generally .2560
How to Disassemble Full Track Shoes Assembly 2560
How to Assemble Full Track Shoes Assembly .2563
Disassemble and Assemble PLUS Type Track Assembly Generally .2575
Disassemble PLUS Type Track Assembly Generally 2576
How to Assemble PLUS Type Track Shoes Assembly Generally 2577
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2592
How to Disassemble One Track Link Assembly in Field (Track Assembly) 2593
How to Assemble One Track Link Assembly in Field (Track Assembly) .2594
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2601
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) .2602
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2604
Remove and Install Equalizer Bar Assembly .2608
How to Remove Equalizer Bar Assembly 2608
How to Install Equalizer Bar Assembly .2610
Disassemble and Assemble Equalizer Bar Bushing 2613
How to Disassemble Equalizer Bar Bushing 2613
How to Assemble Equalizer Bar Bushing .2613
Hydraulic System 2615
Remove and Install Hydraulic Tank Assembly 2615
How to Remove Hydraulic Tank Assembly .2615
How to Install Hydraulic Tank Assembly 2618
Remove and Install HSS Pump and Cooling Fan Pump Assembly .2623
How to Remove HSS Pump and Cooling Fan Pump Assembly 2623
How to Install HSS Pump and Cooling Fan Pump Assembly .2624
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2627
How to Remove Power Train Pump and Steering Lubrication Pump Assembly .2627
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2629
Remove and Install Scavenging Pump Assembly .2632
How to Remove Scavenging Pump Assembly 2632
How to Install Scavenging Pump Assembly .2632
Remove and Install 5 Spool Control Valve Assembly .2634
How to Remove 5 Spool Control Valve Assembly 2634
How to Install 5 Spool Control Valve Assembly .2636
Remove and Install 4 Spool Control Valve Assembly .2639
How to Remove 4 Spool Control Valve Assembly 2639
How to Install 4 Spool Control Valve Assembly .2642
Disassemble and Assemble Blade PPC Valve 2645
How to Disassemble Blade PPC Valve 2645
How to Assemble Blade PPC Valve .2645
Disassemble and Assemble Ripper PPC Valve .2647
How to Disassemble Ripper PPC Valve .2647
How to Assemble Ripper PPC Valve 2647
Work Equipment 2649
Remove and Install Straight Tilt Power Pitch Dozer Blade Assembly .2649
How to Remove Straight Tilt Power Pitch Dozer Blade Assembly 2649
How to Install Straight Tilt Power Pitch Dozer Blade Assembly .2651
Remove and Install Power Angle Power Tilt Dozer Blade Assembly 2655
How to Remove Power Angle Power Tilt Dozer Blade Assembly .2655
How to Install Power Angle Power Tilt Dozer Blade Assembly 2657
Remove and Install Ripper Assembly 2660
How to Remove Ripper Assembly .2660
How to Install Ripper Assembly 2663
How to Disassemble and Assemble Work Equipment Cylinder Assembly 2666
How to Disassemble Work Equipment Cylinder Assembly .2667
How to Assemble Work Equipment Cylinder Assembly 2670
CAB Related Parts .2675
Remove and Install Operator Cab Assembly 2675
How to Remove Operator Cab Assembly .2675
How to Install Operator Cab Assembly 2683
Remove and Install Operator Cab Glass (Adhered Glass) .2691
How to Remove Operator Cab Glass (Adhered Glass) 2691
How to Install Operator Cab Glass (Adhered Glass) .2692
Remove and Install Air Conditioner Unit Assembly 2697
How to Remove Air Conditioner Unit Assembly .2697
How to Install Air Conditioner Unit Assembly 2703
Remove and Install Operator Seat 2710
How to Remove Operator Seat .2710
How to Install Operator Seat 2712
How to Remove and Install Seat Belt .2715
How to Remove Seat Belt .2715
How to Install Seatbelt .2716
Electrical System .2717
Remove and Install Engine Controller Assembly .2717
How to Remove Engine Controller Assembly 2717
How to Install Engine Controller Assembly .2718
Remove and Install Power Train Controller Assembly 2721
How to Remove Power Train Controller Assembly .2721
How to Install Power Train Controller Assembly 2722
Remove and Install Machine Monitor Assembly .2724
How to Remove Machine Monitor Assembly 2724
How to Install Machine Monitor Assembly .2725
Remove and Install Mass Air Flow and Temperature Sensor .2727
How to Remove Mass Air Flow and Temperature Sensor 2727
How to Install Mass Air Flow and Temperature Sensor .2728
Remove and Install KCCV Crankcase Pressure Sensor .2729
How to Remove KCCV Crankcase Pressure Sensor 2729
How to Install KCCV Crankcase Pressure Sensor .2730
Remove and Install SCR Temperature Sensor .2731
How to Remove SCR Temperature Sensor 2731
How to Install SCR Temperature Sensor .2732
Remove and Install Rearview Camera 2734
How to Remove Rearview Camera .2734
How to Install Rearview Camera 2734
Remove and Install Gateway Function Controller Assembly .2736
How to Remove Gateway Function Controller Assembly 2736
How to Install Gateway Function Controller Assembly .2739
Remove and Install Communication Terminal .2744
How to Remove Communication Terminal 2744
How to Install Communication Terminal .2747
60 Maintenance Standard .2751
Table of Contents .2752
Explanation of Terms for Maintenance Standard .2754
Engine and Cooling System .2756
Maintenance Standard for Engine Mount .2756
Maintenance Standard for Damper .2757
Maintenance Standard for Cooling System .2759
Maintenance Standard for Cooling Fan Pump .2761
Maintenance Standard for Servo Valve 2762
Maintenance Standard for Cooling Fan Motor 2763
Power Train .2765
Maintenance Standard for Universal Joint 2765
Maintenance Standard for Power Train Mount 2766
Maintenance Standard for Torque Converter and PTO .2768
Maintenance Standard for Lockup Clutch ECMV .2771
Maintenance Standard for Transmission .2772
Maintenance Standard for Transmission Control Valve .2777
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV .2778
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 2779
Maintenance Standard for Transmission Lubrication Relief Valve 2780
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake .2781
Maintenance Standard for Brake Valve 2786
Maintenance Standard for Final Drive 2788
Maintenance Standard for Sprocket for Conventional Type Track Shoes .2790
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2791
Maintenance Standard for Sprocket for PLUS Type Track Shoes .2793
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2794
Undercarriage and Frame .2796
Maintenance Standard for Main Frame .2796
Maintenance Standard for Suspension .2797
Maintenance Standard for Track Frame and Idler Cushion 2799
Maintenance Standard for Idler 2801
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2803
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2804
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2805
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2806
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes .2807
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes .2808
Maintenance Standard for Conventional Type Track Shoes 2809
Maintenance Standard for PLUS Type Track Shoes 2811
Maintenance Standard for Single Shoes .2813
Maintenance Standard for Swamp Shoes 2814
Hydraulic System 2815
Maintenance Standard for Hydraulic Tank .2815
Maintenance Standard for Scavenging Pump 2816
Maintenance Standard for Steering Lubrication Pump and Power Train Pump .2817
Maintenance Standard for Work Equipment and HSS Pump 2818
Maintenance Standard for PC-EPC Valve .2819
Maintenance Standard for HSS Motor 2820
Maintenance Standard for Control Valve 2822
Maintenance Standard for Blade PPC Valve 2830
Maintenance Standard for Ripper PPC Valve .2832
Maintenance Standard for Angle Control EPC Valve 2834
Maintenance Standard for Quick Drop Valve .2835
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer and Angle Dozer Series) .2837
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Tilt Pitch Dozer Series) .2838
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Angle Power Tilt Dozer Series) .2839
Work Equipment 2840
Maintenance Standard for Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series) 2840
Maintenance Standard for Front Work Equipment (For Power Angle Power Tilt Dozer Series) .2843
Maintenance Standard for Front Work Equipment (Angle Dozer Series) 2846
Maintenance Standard for Cutting Edge and End Bit .2849
Maintenance Standard for Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series) 2851
Maintenance Standard for Blade Lift Cylinder (For Power Angle Power Tilt Dozer Series) 2852
Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series) 2853
Maintenance Standard for Blade Tilt Cylinder (For Power Angle Power Tilt Dozer Series) 2854
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series) .2855
Maintenance Standard for Blade Angle Cylinder (For Power Angle Power Tilt Dozer Series) .2856
Maintenance Standard for Fixed Multi-Shank Ripper .2857
Maintenance Standard for Ripper Lift Cylinder .2858
CAB Related Parts .2859
Maintenance Standard for CAB Mount 2859
80 Appendix .2861
Table of Contents .2862
Precautions Before Work .2864
Air Conditioner System 2865
Precautions for Refrigerant .2865
Air Conditioner Component .2866
Specifications of Air Conditioner .2868
Structure and Function of Refrigeration Cycle .2869
Outline of Refrigeration Cycle 2870
Component Parts of Air Conditioner System .2872
Air Conditioner Unit 2872
Configuration Diagram of Air Conditioner Unit .2872
Function of Air Conditioner Unit 2874
Component Parts of Air Conditioner Unit .2876
Function of Evaporator as Air Conditioner Unit Component 2877
Function of Heater Core as Air Conditioner Unit Component .2877
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .2877
Function of Servo Motor as Air Conditioner Unit Component .2877
Structure of Expansion Valve as Air Conditioner Unit Component 2878
Function of Expansion Valve as Air Conditioner Unit Component .2878
Operate Expansion Valve as Air Conditioner Unit Component .2878
Function of Dual Pressure Switch 2879
Air Conditioner Controller 2880
Structure of Air Conditioner Controller .2880
Compressor 2881
Structure of Compressor .2881
Specifications of Compressor 2881
Function of Compressor 2881
Condenser .2882
Structure of Standard Core Condenser 2882
Specifications of Standard Core Condenser .2882
Function of Standard Core Condenser .2882
Structure of Wide Core Condenser 2883
Specifications of Wide Core Condenser .2883
Function of Wide Core Condenser .2883
Receiver Drier 2884
Structure of Receiver Dryer .2884
Specifications of Receiver Dryer 2884
Function of Receiver Dryer 2884
Air Conditioner Related Sensors .2885
Structure of Sunlight Sensor 2885
Function of Sunlight Sensor .2885
Structure of Outside Temperature Sensor .2885
Function of Outside Air Temperature Sensor 2885
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .2887
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2889
System Diagram of Air Conditioner .2891
Input and Output Signals of Air Conditioner Controller 2892
Function of Air Conditioner Controller 2893
Locations of Air Conditioner Parts and Layout of Connectors .2894
Examine Air Leakage (Duct) 2903
How to Examine Air Leakage (Duct) .2903
Explanation for Test of Air Conditioner with Self-Diagnosis Function 2906
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .2907
Examine Vent (Mode) Changeover 2908
How to Examine Vent (Mode) Changeover .2908
Examine Fresh/Recirc Air Changeover .2909
How to Examine Fresh/Recirc Air Changeover 2909
Examine Sunlight Sensor .2910
How to Examine Sunlight Sensor 2910
Examine Refrigerant (Dual) Pressure Switch 2911
How to Examine Refrigerant (Dual) Pressure Switch .2911
Examine Relay .2912
How to Examine Relay 2912
Air Conditioner Troubleshooting Chart 1 .2913
Air Conditioner Troubleshooting Chart 2 .2914
Information Shown in Troubleshooting Table 2917
Failure Code [879AKA] .2918
Failure Code [879AKB] .2919
Failure Code [879BKA] .2920
Failure Code [879BKB] .2922
Failure Code [879CKA] .2924
Failure Code [879CKB] .2925
Failure Code [879DKZ] .2926
Failure Code [879EMC] .2928
Failure Code [879FMC] .2929
Failure Code [879GKX] .2930
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2932
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .2934
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2938
Troubleshooting for Fresh/Recirc Air Changeover .2940
Troubleshooting by Gauge Pressure .2942
Connect Service Tool 2945
How to Connect Service Tool .2945
Precautions for Disconnection and Connection of Air Conditioner Piping 2947
Handle Compressor Oil .2949
90 Circuit Diagrams .2951
Table of Contents .2952
How to Read the Codes for Electric Cable 2953
Hydraulic Circuit Diagram .2957
Symbols Used in Hydraulic Circuit Diagram .2957
Hydraulic Circuit Diagram (For Straight Tilt and SIGMADOZER) 2961
Hydraulic Circuit Diagram (For Straight Tilt Power Pitch Dozer) .2963
Hydraulic Circuit Diagram (For Power Angle Power Tilt Dozer) 2965
Hydraulic Circuit Diagram (For Straight Tilt and SIGMADOZER) (3D Machine Control Spec) 2967
Hydraulic Circuit Diagram (For Straight Tilt Power Pitch Dozer) (3D Machine Control Spec) .2969
Hydraulic Circuit Diagram (For Power Angle Power Tilt Dozer) (3D Machine Control Spec) 2971
Power Train Hydraulic Circuit Diagram .2973
Electrical Circuit Diagram 2975
Symbols Used in Electric Circuit Diagram 2975
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (1/18) 2979
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (2/18) 2981
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (3/18) 2983
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (4/18) 2985
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (5/18) 2987
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (6/18) 2989
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (7/18) 2991
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (8/18) 2993
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (9/18) 2995
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (10/18) .2997
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (11/18) .2999
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (12/18) .3001
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (13/18) .3003
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (14/18) .3005
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (15/18) .3007
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (16/18) .3009
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (17/18) .3011
Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (18/18) .3013
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (1/18) 3015
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (2/18) 3017
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (3/18) 3019
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (4/18) 3021
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (5/18) 3023
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (6/18) 3025
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (7/18) 3027
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (8/18) 3029
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (9/18) 3031
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (10/18) .3033
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (11/18) .3035
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (12/18) .3037
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (13/18) .3039
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (14/18) .3041
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (15/18) .3043
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (16/18) .3045
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (17/18) .3047
Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (18/18) .3049
Index 3051

DESCRIPTION:

Komatsu Bulldozer D65EX -18,D65PX -18,D65WX-18 Shop Manual SEN06900-04  – PDF DOWNLOAD

• SERIAL NUMBERS
  D65EX- 96001            and up
  D65PX- 96001            and up
  D65WX-96001            and up

G.B 27/12/24