Komatsu BULLDOZER D65EX-18M0 Shop Manual SEN06966-01 – PDF DOWNLOAD
$33.95
Komatsu BULLDOZER D65EX-18M0 Shop Manual SEN06966-01 – PDF DOWNLOAD
SERIAL NUMBERS 96001 and up
Description
Komatsu BULLDOZER D65EX-18M0 Shop Manual SEN06966-01 – PDF DOWNLOAD
FILE DETAILS:
Komatsu BULLDOZER D65EX-18M0 Shop Manual SEN06966-01 – PDF DOWNLOAD
Language : English
Pages :2960
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu BULLDOZER D65EX-18M0 Shop Manual SEN06966-01 – PDF DOWNLOAD
SERIAL NUMBERS 90001 and up
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 “AdBlue/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 “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/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.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.
TABLE OF CONTENTS:
Komatsu BULLDOZER D65EX-18M0 Shop Manual SEN06966-01 – PDF DOWNLOAD
SERIAL NUMBERS 96001 and up
Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 21
How to Read the Shop Manual 21
Safety Notice for Operation 23
Precautions to Prevent Fire 31
Procedures If Fire Occurs 33
Precautions When You Discard Waste Materials 34
Actions Taken to Meet Exhaust Gas Regulations 35
Precautions for DEF 36
General Character and Precautions for Handling 36
Precautions When You Add 36
Precautions for Storage 36
Precautions for Fire Hazard and Leakage 36
Other Precautions 36
Store DEF 37
Precautions When You Handle Hydraulic Equipment 38
Precautions When You Disconnect and Connect Pipings 41
Precautions When You Handle Electrical Equipment 48
Precautions When You Handle Fuel System Equipment 50
Precautions When You Handle Intake System Equipment 51
Practical Use of KOMTRAX 52
Disconnect and Connect Push-Pull Type Coupler 53
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 53
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 54
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 55
Precautions for Disconnection and Connection of Connectors 57
Disconnect and Connect Deutsch Connector 61
How to Disconnect and Connect Slide Lock Type Connector 62
Disconnect and Connect Connector with Lock to Pull 64
Disconnect and Connect Connector with Lock to Push 65
Disconnect and Connect Connector with Housing to Rotate 67
How to Read the Codes for Electric Cable 68
Explanation of Terms for Maintenance Standard 72
Standard Tightening Torque Table 75
Conversion Table 82
Abbreviation List 87
01 Specification 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: D65EX-18M0 93
Specifications 95
Specifications: D65EX-18M0 95
Weight Table 100
Weight Table: D65EX-18M0 100
Fuel, Coolant, Lubricant 102
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 102
10 Structure and Function 105
Table of Contents 106
Urea SCR System 109
Layout Drawing of Urea SCR System 109
Urea SCR System Diagram 111
Function of Urea SCR System 112
Function of DEF System 112
Inducement Strategy 114
Component Parts of Urea SCR System 133
DEF Mixing Tube 133
SCR Assembly 133
DEF Tank 136
DEF Pump 138
DEF Injector 139
DEF Hose 140
DEF Tank Heating Valve 141
Boot-up System 142
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 142
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 144
System Operating Lamp System 146
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 146
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 146
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 146
Function of Operation Lamp System (Machine with Gateway Function Controller) 147
Battery Disconnect Switch 149
Layout Drawing of Battery Disconnect Switch 149
Function of Battery Disconnect Switch 149
Engine System 151
Layout Drawing of Engine System 151
Engine Control System 153
Layout of Engine Control System (Machine with KOMTRAX Terminal) 153
Layout of Engine Control System (Machine with Gateway Function Controller) 155
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) 156
System Diagram of Engine Control System (Machine with Gateway Function Controller) 158
Function of Engine Control System (Machine with KOMTRAX Terminal) 160
Function of Engine Control System (Machine with Gateway Function Controller) 162
Automatic Idle Stop System 164
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 164
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) 165
Function of Automatic Idle Stop System 165
Component Parts of Engine System 168
Damper 168
VGT 169
EGR System 173
EGR Valve 175
EGR Cooler 177
KCCV System 178
KCCV Ventilator 180
KDPF 182
Cooling System 187
Layout Drawing of Cooling System 187
Specifications of Cooling System 188
Layout Drawing of Cooling System (Trimming Dozer Specification) 189
Specifications of Cooling System (Trimming Dozer Specification) 190
Cooling Fan Control System 191
System Diagram of Cooling Fan Control System 191
Function of Cooling Fan Control System 192
Component Parts of Cooling System 194
Cooling Fan Pump 194
Cooling Fan Motor 203
Hydraulic Oil Cooler Bypass Valve 210
Control System 211
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 211
Layout Drawing of Control System (Machine with Gateway Function Controller) 212
Machine Monitor System 213
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 213
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 214
Function of Machine Monitor System 214
KOMTRAX System 215
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 215
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 215
Function of KOMTRAX System 216
Component Parts of Control System 217
Machine Monitor 217
KOMTRAX Terminal 234
Gateway Function Controller 236
Communication Terminal 239
Power Train Controller 241
Engine Controller 245
Hydraulic System 252
Layout Drawing of Hydraulic System 252
CLSS 253
Structure of CLSS 253
Function of CLSS 254
Component Parts of Hydraulic System 256
Hydraulic Tank 256
Work Equipment and HSS Pump 257
LS Valve 262
PC Valve 267
PC-EPC Valve 272
Control Valve 276
Power Train System 307
Layout Drawing of Power Train System 307
Operation of Power Train System 310
Transmission, Steering, and Brake Control 311
Layout Drawing of Transmission, Steering, and Brake Control System 311
Function of Transmission, Steering, and Brake Control 312
Palm Command Control System 313
Palm Command Control System Diagram 313
HSS System 317
HSS System Diagram 317
Function of HSS System 318
Centralized Pressure Pickup Port 320
Layout Drawing of Centralized Pressure Pickup Port 320
Function of Centralized Pressure Pickup Port 320
Component Parts of Power Train System 321
Universal Joint 321
Power Train Mount 322
Torque Converter and PTO 323
Lockup Clutch ECMV 328
Transmission 332
Transmission Control Valve 344
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 345
Main Relief Valve and Torque Converter Relief Valve 350
Transmission Lubrication Relief Valve 352
Bevel Gear Shaft, HSS, and Brake 353
Brake Valve 372
Final Drive 376
Scavenging Pump 379
Steering Lubrication Pump and Power Train Pump 380
HSS Motor 381
Electric Steering Electric Lever 386
Work Equipment System 390
Work Equipment Control 390
Layout Drawing of Work Equipment Control 390
Function of Work Equipment Control 391
Layout Drawing of Tilt Dozer, Power Tilt Pitch Dozer, Angle Dozer and Semi-U Dozer Series 393
Layout Drawing of Fixed Multi-Shank Ripper 395
Component Parts of Work Equipment System 396
Self-Pressure Reducing Valve 396
Work Equipment Lock Solenoid Valve 402
Blade PPC Valve 404
Ripper PPC Valve 410
Blade Pitch Selector Solenoid Valve 413
Pilot Circuit Accumulator 415
Quick Drop Valve 416
Piston Valve 417
Undercarriage and Frame 419
Main Frame 419
Structure of Main Frame 419
Suspension 421
Structure of Suspension 421
Specifications of Suspension 422
Function of Suspension 423
Track Frame and Idler Cushion 424
Structure of Track Frame and Idler Cushion 424
Function of Track Frame and Idler Cushion 426
Work Equipment 427
Structure of Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series) 427
Structure of Front Work Equipment (Angle Dozer Series) 428
Structure of Front Work Equipment (Trimming Dozer Specification) 429
Structure of Fixed Multi-Shank Ripper 430
CAB Related Parts 431
ROPS CAB 431
Structure of ROPS CAB 431
Function of ROPS CAB 432
CAB Mount 433
Structure of CAB Mount 433
Function of CAB Mount 433
20 Standard Value Table 435
Table of Contents 436
Standard Value Table for Engine 437
Standard Value Table for Engine: D65EX-18M0 437
Standard Value Table for Machine 442
Standard Value Table for Machine: D65EX-18M0 442
Machine Posture and Procedures to Measure Performance 458
30 Testing and Adjusting 461
Table of Contents 462
Precautions Before Work 465
Related Information on Testing and Adjusting 466
Tools for Testing and Adjusting 466
Sketch of Tools for Testing and Adjusting 472
Engine and Cooling System 473
Examine Engine Speed 473
How to Examine Engine Speed 473
Examine Boost Pressure 476
How to Examine Boost Pressure 476
Examine Exhaust Gas Temperature 478
How to Examine Exhaust Gas Temperature 478
Examine Exhaust Gas Color 480
How to Examine Exhaust Gas Color with the Handy Smoke Checker 480
How to Examine Exhaust Gas Color with Smoke Meter 480
Examine Mass Air Flow and Temperature Sensor 482
How to Examine Mass Air Flow and Temperature Sensor 482
Examine and Adjust Valve Clearance 484
Check Valve Clearance 484
Adjust Valve Clearance 485
Examine Compression Pressure 487
How to Examine Compression Pressure 487
Examine Blowby Pressure 489
How to Examine Blowby Pressure 489
Examine Engine Oil Pressure 492
How to Examine Engine Oil Pressure 492
Examine EGR Valve and VGT Oil Pressure 493
How to Examine EGR Valve and VGT Oil Pressure 493
Examine Fuel Pressure 495
How to Examine Fuel Pressure 496
Examine Fuel Discharge, Return and Leakage 502
How to Examine Fuel Discharge, Return, and Leakage 503
Bleed Air from Fuel System 507
How to Bleed Air from Fuel System 507
Examine Fuel Circuit for Leakage 509
How to Examine Fuel System for Leakage 509
Handle Cylinder Cut-out Mode Operation 511
Handle No-Injection Cranking Operation 512
Examine and Adjust Air Conditioner Compressor Belt Tension 513
How to Examine Air Conditioner Compressor Belt Tension 513
How to Adjust Air Conditioner Compressor Belt Tension 513
Examine Alternator Belt 514
How to Examine Alternator Belt 514
Examine Automatic Tensioner 516
How to Examine Automatic Tensioner 516
Write Correction for Ash in Soot Accumulation to Engine Controller 518
How to Write Correction for Ash in Soot Accumulation to Engine Controller 518
Examine SCR Related Functions 519
Examine DEF Pump Raised Pressure 523
Examine Injection Volume from DEF Injector 526
Examine DEF Line Heater Relay 1 531
Examine DEF Line Heater Relay 2 534
Examine DEF Pump Heater Relay 537
Examine DEF Tank Heater Valve 540
Examine SCR Denitration Efficiency 543
Clean DEF Tank 546
How to Clean DEF Tank 546
Clean DEF Tank Mounting Part 550
How to Clean DEF Tank Mounting Part 550
Clean DEF Pump 552
How to Clean DEF Pump 552
Adjust Decelerator Pedal 558
How to Adjust Decelerator Pedal 558
Power Train 560
Examine Power Train Oil Pressure 560
How to Examine Power Train Oil Pressure 561
Adjust Transmission Output Shaft Speed Sensor 572
How to Adjust Transmission Output Shaft Speed Sensor 572
Examine Brake Performance Simply 574
How to Examine Brake Performance Simply 574
Adjust Brake Pedal 575
How to Adjust Brake Pedal 575
Adjust Parking Brake Lever 577
How to Adjust Parking Brake Lever 577
Move Machine by Parking Brake Release When Machine Does Not Travel 579
Move Machine with Hydraulic Type Parking Brake Release System 579
Move Machine with Electric Type Parking Brake Release System 580
Undercarriage and Frame 582
Adjust Idler Clearance 582
How to Adjust Idler Clearance 582
Examine and Adjust Track Tension 583
How to Examine Track Tension 583
How to Adjust Track Tension 583
Hydraulic System 584
Release Remained Pressure in Hydraulic Circuit 584
How to Release Remained Pressure in Hydraulic System 584
Examine and Adjust Work Equipment and HSS Oil Pressure 585
How to Examine Work Equipment and HSS Oil Pressure 585
Adjust Oil Pressure of Work Equipment and HSS 588
Examine Oil Pressure of Control Circuit 590
How to Examine Oil Pressure in Control Circuit 590
Examine PPC Valve Outlet Pressure 592
Examine Outlet Pressure in PPC Valve 592
Bleed Air from HSS Pump 594
How to Bleed Air from HSS Pump 594
Examine and Adjust Play of Work Equipment PPC Valve 595
How to Examine Play of Work Equipment PPC Valve 595
How to Adjust Play of Work Equipment PPC Valve 596
Examine Cooling Fan Speed 597
How to Examine Cooling Fan Speed 597
Examine Cooling Fan Circuit Oil Pressure 598
How to Examine Cooling Fan Circuit Oil Pressure 598
Bleed Air in Cooling Fan Pump 600
How to Bleed Air in Cooling Fan Pump 600
Examine Parts Which Cause Hydraulic Drift of Work Equipment 601
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 601
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 601
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 602
Examine Oil Leakage from Work Equipment Cylinder 603
How to Examine Internal Oil Leakage of Work Equipment Cylinder 603
Bleed Air from Work Equipment Cylinders 605
Bleed Air from Work Equipment Cylinder 605
Work Equipment 606
Adjust Work Equipment Lock Lever 606
How to Adjust Work Equipment Lock Lever 606
CAB Related Parts 608
Examine and Adjust Operator Cab 608
Examine Operator Cab 608
Adjust Operator Cab 610
Electrical System 613
Set and Operate Machine Monitor 613
Operator Mode 617
Function to Show Technician Identification Status Screen 617
Function to Show Operator Identification Input Screen 617
Examine Function by LCD (Liquid Crystal Display) 618
Examine Function of Service Meter 618
Usage Limitation and Change Maintenance Password 618
Service Mode 621
How to Operate Service Mode 621
How to See Pre-defined Monitoring Information 622
How to Examine Monitoring Information 628
Abnormality Record Menu 639
How to See Maintenance Record 643
Maintenance Mode Setting 645
Set Phone Number Entry 648
Default Setting Menu 650
Testing Menu 659
Adjustment Menu 668
No-Injection Cranking Operation 696
KOMTRAX Settings Menu 698
Show Service Message 702
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 704
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 709
Start Up KOMTRAX System (Machine with Gateway Function Controller) 711
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 717
Adjust When Power Train Controller is Replaced 719
How to Adjust When Power Train Controller is Replaced 719
Adjust Rearview Camera Angle 722
How to Adjust Rearview Camera Angle 722
Set Region of Bluetooth(R) Compatible Radio 723
Set Region of Bluetooth(R) Compatible Radio 723
Handle Voltage Circuit of Engine Controller 725
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 726
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 727
Examine Diodes 728
Examine Diodes by Digital Tester 728
How to Examine Diodes by Analog Tester 728
Pm Clinic 729
Pm Clinic Service 729
Pm Clinic Check Sheet: D65EX-18M0 731
Pm Clinic Check Sheet for Undercarriage: D65EX-18M0 743
40 Troubleshooting 751
Table of Contents 752
Precautions Before Work 762
Related Information to Troubleshooting 763
General Troubleshooting Points 763
Troubleshooting Points for Failure Codes of Inducement 764
Sequence of Events in Troubleshooting 777
Checks Before Troubleshooting 779
Inspection Procedure Before Troubleshooting 781
Walk-Around Check 781
Test in Accordance with Testing Procedure 783
How to Examine Electric Equipment 783
Preparation for Troubleshooting of Electrical System 791
Procedure for Troubleshooting 798
Symptom and Troubleshooting Numbers 801
Information Shown in Troubleshooting Table 804
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 806
Connector List and Layout 808
Connector Contact Connection Table 830
T-Branch Box and T-Branch Adapter Table 870
Fuse Location Table 876
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 879
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 882
Failure Code Table 884
Troubleshooting by Failure Code (Display of Code) 903
Failure Code [1500L0] 903
Failure Code [15SAL1] 904
Failure Code [15SALH] 906
Failure Code [15SBL1] 908
Failure Code [15SBLH] 910
Failure Code [15SEL1] 912
Failure Code [15SELH] 914
Failure Code [15SFL1] 916
Failure Code [15SFLH] 918
Failure Code [15SGL1] 920
Failure Code [15SGLH] 922
Failure Code [15SJL1] 924
Failure Code [15SJLH] 926
Failure Code [1800MW] 928
Failure Code [879AKA] 929
Failure Code [879AKB] 930
Failure Code [879BKA] 931
Failure Code [879BKB] 933
Failure Code [879CKA] 935
Failure Code [879CKB] 936
Failure Code [879DKZ] 937
Failure Code [879EMC] 939
Failure Code [879FMC] 940
Failure Code [879GKX] 941
Failure Code [989L00] 943
Failure Code [989M00] 944
Failure Code [989N00] 945
Failure Code [A1U0N3] 946
Failure Code [A1U0N4] 948
Failure Code [A900FR] 950
Failure Code [A900N6] 951
Failure Code [A900NY] 952
Failure Code [AA10NX] 953
Failure Code [AB00KE] 955
Failure Code [AQ10N3] 957
Failure Code [AS00N3] 959
Failure Code [AS00R2] 961
Failure Code [AS00R3] 962
Failure Code [AS00R4] 963
Failure Code [AS00R6] 964
Failure Code [AS10KM] 965
Failure Code [AS10NR] 966
Failure Code [AS10NT] 967
Failure Code [B@BAZG] 968
Failure Code [B@BCNS] 969
Failure Code [B@BCQA] 970
Failure Code [B@BCZK] 972
Failure Code [B@CENS] 974
Failure Code [B@HANS] 975
Failure Code [CA115] 976
Failure Code [CA122] 977
Failure Code [CA123] 979
Failure Code [CA131] 981
Failure Code [CA132] 983
Failure Code [CA144] 986
Failure Code [CA145] 988
Failure Code [CA153] 990
Failure Code [CA154] 993
Failure Code [CA187] 996
Failure Code [CA221] 998
Failure Code [CA222]1000
Failure Code [CA227]1002
Failure Code [CA234]1003
Failure Code [CA238]1004
Failure Code [CA239]1006
Failure Code [CA249]1008
Failure Code [CA256]1010
Failure Code [CA271]1012
Failure Code [CA272]1014
Failure Code [CA281]1016
Failure Code [CA322]1017
Failure Code [CA323]1019
Failure Code [CA324]1021
Failure Code [CA325]1023
Failure Code [CA331]1025
Failure Code [CA332]1027
Failure Code [CA343]1029
Failure Code [CA351]1030
Failure Code [CA352]1031
Failure Code [CA356]1034
Failure Code [CA357]1036
Failure Code [CA386]1038
Failure Code [CA428]1039
Failure Code [CA429]1041
Failure Code [CA435]1043
Failure Code [CA441]1045
Failure Code [CA442]1047
Failure Code [CA449]1048
Failure Code [CA451]1052
Failure Code [CA452]1055
Failure Code [CA515]1057
Failure Code [CA516]1059
Failure Code [CA553]1061
Failure Code [CA555]1062
Failure Code [CA556]1063
Failure Code [CA559]1064
Failure Code [CA595]1068
Failure Code [CA687]1069
Failure Code [CA689]1071
Failure Code [CA691]1076
Failure Code [CA692]1078
Failure Code [CA697]1080
Failure Code [CA698]1081
Failure Code [CA731]1082
Failure Code [CA778]1084
Failure Code [CA1117]1089
Failure Code [CA1664]1090
Failure Code [CA1669]1093
Failure Code [CA1673]1094
Failure Code [CA1677]1095
Failure Code [CA1678]1096
Failure Code [CA1682]1097
Failure Code [CA1683]1102
Failure Code [CA1684]1104
Failure Code [CA1686]1106
Failure Code [CA1691]1107
Failure Code [CA1694]1110
Failure Code [CA1695]1113
Failure Code [CA1696]1114
Failure Code [CA1712]1116
Failure Code [CA1713]1119
Failure Code [CA1714]1121
Failure Code [CA1715]1122
Failure Code [CA1776]1123
Failure Code [CA1777]1126
Failure Code [CA1843]1129
Failure Code [CA1844]1131
Failure Code [CA1879]1134
Failure Code [CA1881]1137
Failure Code [CA1883]1140
Failure Code [CA1885]1144
Failure Code [CA1887]1146
Failure Code [CA1922]1148
Failure Code [CA1942]1152
Failure Code [CA1993]1153
Failure Code [CA2185]1156
Failure Code [CA2186]1158
Failure Code [CA2249]1160
Failure Code [CA2265]1161
Failure Code [CA2266]1163
Failure Code [CA2271]1165
Failure Code [CA2272]1168
Failure Code [CA2311]1171
Failure Code [CA2349]1172
Failure Code [CA2353]1175
Failure Code [CA2357]1177
Failure Code [CA2381]1178
Failure Code [CA2382]1181
Failure Code [CA2383]1184
Failure Code [CA2386]1187
Failure Code [CA2387]1189
Troubleshooting Flowchart1193
Failure Code [CA2555]1194
Failure Code [CA2556]1197
Failure Code [CA2637]1200
Failure Code [CA2771]1202
Failure Code [CA2777]1208
Failure Code [CA2976]1211
Failure Code [CA3133]1213
Failure Code [CA3134]1215
Failure Code [CA3135]1218
Failure Code [CA3142]1222
Failure Code [CA3143]1223
Failure Code [CA3144]1224
Failure Code [CA3146]1226
Failure Code [CA3147]1227
Failure Code [CA3148]1228
Failure Code [CA3151]1230
Failure Code [CA3165]1236
Failure Code [CA3229]1239
Failure Code [CA3231]1241
Failure Code [CA3232]1243
Failure Code [CA3235]1247
Failure Code [CA3239]1249
Failure Code [CA3241]1252
Failure Code [CA3242]1255
Failure Code [CA3251]1258
Failure Code [CA3253]1260
Failure Code [CA3254]1263
Failure Code [CA3255]1266
Failure Code [CA3256]1270
Failure Code [CA3311]1272
Failure Code [CA3312]1274
Failure Code [CA3313]1277
Failure Code [CA3314]1278
Failure Code [CA3315]1279
Failure Code [CA3316]1282
Failure Code [CA3317]1284
Failure Code [CA3318]1285
Failure Code [CA3319]1288
Failure Code [CA3321]1289
Failure Code [CA3322]1291
Failure Code [CA3419]1294
Failure Code [CA3421]1296
Failure Code [CA3545]1298
Failure Code [CA3547]1300
Failure Code [CA3558]1301
Failure Code [CA3559]1303
Failure Code [CA3562]1305
Failure Code [CA3563]1307
Failure Code [CA3567]1310
Failure Code [CA3568]1313
Failure Code [CA3571]1319
Failure Code [CA3572]1321
Failure Code [CA3574]1323
Failure Code [CA3575]1326
Failure Code [CA3577]1328
Failure Code [CA3578]1330
Failure Code [CA3582]1332
Failure Code [CA3583]1341
Failure Code [CA3596]1343
Failure Code [CA3649]1346
Failure Code [CA3681]1349
Failure Code [CA3682]1352
Failure Code [CA3713]1355
Failure Code [CA3717]1358
Failure Code [CA3718]1359
Failure Code [CA3725]1360
Failure Code [CA3741]1363
Failure Code [CA3748]1364
Failure Code [CA3751]1367
Failure Code [CA3755]1369
Failure Code [CA3866]1372
Failure Code [CA3867]1376
Failure Code [CA3868]1379
Failure Code [CA3899]1383
Failure Code [CA3911]1385
Failure Code [CA3912]1389
Failure Code [CA3932]1391
Failure Code [CA3933]1393
Failure Code [CA3934]1395
Failure Code [CA3935]1398
Failure Code [CA3936]1400
Failure Code [CA4151]1402
Failure Code [CA4152]1407
Failure Code [CA4155]1411
Failure Code [CA4156]1414
Failure Code [CA4157]1417
Failure Code [CA4158]1419
Failure Code [CA4159]1420
Failure Code [CA4161]1421
Failure Code [CA4162]1424
Failure Code [CA4163]1427
Failure Code [CA4164]1429
Failure Code [CA4165]1431
Failure Code [CA4166]1433
Failure Code [CA4168]1435
Failure Code [CA4169]1438
Failure Code [CA4171]1440
Failure Code [CA4249]1443
Failure Code [CA4251]1445
Failure Code [CA4259]1447
Failure Code [CA4261]1450
Failure Code [CA4277]1453
Failure Code [CA4281]1456
Failure Code [CA4459]1460
Failure Code [CA4461]1463
Failure Code [CA4658]1466
Failure Code [CA4731]1470
Failure Code [CA4732]1471
Failure Code [CA4739]1472
Failure Code [CA4768]1473
Failure Code [CA4769]1475
Failure Code [CA4842]1478
Failure Code [CA4952] (Machine with KOMTRAX Terminal)1481
Failure Code [CA4952] (Machine with Gateway Function Controller)1483
Failure Code [CA5115]1485
Failure Code [CA5383]1488
Failure Code [D130KA]1490
Failure Code [D130KB]1493
Failure Code [D19JKZ]1495
Failure Code [D811MC] (Machine with KOMTRAX Terminal)1498
Failure Code [D811MC](Machine with Gateway Function Controller)1499
Failure Code [D862KA] (Machine with KOMTRAX Terminal)1500
Failure Code [D862KA](Machine with Gateway Function Controller)1501
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)1502
Failure Code [D8ALKA](Machine with Gateway Function Controller)1504
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)1506
Failure Code [D8ALKB](Machine with Gateway Function Controller)1508
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)1511
Failure Code [D8AQKR](Machine with Gateway Function Controller)1513
Failure Code [D8ARKR]1515
Failure Code [D8G1KT]1518
Failure Code [D8G6KT]1519
Failure Code [DAF0MB]1520
Failure Code [DAF0MC]1521
Failure Code [DAF8KB]1522
Failure Code [DAF9KQ]1523
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)1524
Failure Code [DAFGMC](Machine with Gateway Function Controller)1525
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)1526
Failure Code [DAFLKA](Machine with Gateway Function Controller)1528
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)1530
Failure Code [DAFLKB](Machine with Gateway Function Controller)1532
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)1535
Failure Code [DAFQKR](Machine with Gateway Function Controller)1536
Failure Code [DAQW00]1537
Failure Code [DAZ9KQ]1538
Failure Code [DAZQKR]1539
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)1540
Failure Code [DB2QKR](Machine with Gateway Function Controller)1545
Failure Code [DB2RKR]1553
Failure Code [DBE0KT]1559
Failure Code [DBE0MC]1560
Failure Code [DBE1KK]1561
Failure Code [DBE2KK]1564
Failure Code [DBE5KK]1567
Failure Code [DBE6KK]1569
Failure Code [DBE7KK]1571
Failure Code [DBE9KQ]1573
Failure Code [DBELKA]1574
Failure Code [DBELKB]1576
Failure Code [DBEQKR]1578
Failure Code [DBERKR]1579
Failure Code [DD12KA]1582
Failure Code [DD12KB]1584
Failure Code [DD13KA]1586
Failure Code [DD13KB]1588
Failure Code [DD14KA]1590
Failure Code [DD14KB]1592
Failure Code [DDKHKA]1594
Failure Code [DDKHKB]1596
Failure Code [DDN7KA]1598
Failure Code [DDN7KB]1600
Failure Code [DDNLKA]1602
Failure Code [DDNLKB]1604
Failure Code [DGS1KA]1606
Failure Code [DGS1KX]1608
Failure Code [DGT1KA]1610
Failure Code [DGT1KX]1613
Failure Code [DH21KA]1615
Failure Code [DH21KY]1617
Failure Code [DHA4KA]1619
Failure Code [DHAAMA]1621
Failure Code [DHACMA]1623
Failure Code [DHTDKA]1625
Failure Code [DHTDKY]1627
Failure Code [DK10KA]1629
Failure Code [DK10KB]1632
Failure Code [DK30KA]1634
Failure Code [DK30KX]1637
Failure Code [DK30KY]1638
Failure Code [DK30KZ]1640
Failure Code [DK30L8]1641
Failure Code [DK31KA]1642
Failure Code [DK31KY]1645
Failure Code [DK40KA]1647
Failure Code [DK40KY]1649
Failure Code [DK55KX]1651
Failure Code [DK55KZ]1652
Failure Code [DK55L8]1653
Failure Code [DK56KA]1654
Failure Code [DK56KY]1656
Failure Code [DK57KA]1658
Failure Code [DK57KY]1660
Failure Code [DKH1KA]1662
Failure Code [DKH1KY]1665
Failure Code [DLM3KA]1667
Failure Code [DLM3MB]1669
Failure Code [DLT3KA]1670
Failure Code [DLT3KB]1672
Failure Code [DR21KX]1674
Failure Code [DR31KX]1675
Failure Code [DV20KB]1676
Failure Code [DW5AKA]1678
Failure Code [DW5AKB]1680
Failure Code [DW5AKY]1682
Failure Code [DW7BKA]1684
Failure Code [DW7BKB]1686
Failure Code [DW7BKY]1688
Failure Code [DWN1KA]1689
Failure Code [DWN1KB]1691
Failure Code [DWN1KY]1693
Failure Code [DWN2KA]1695
Failure Code [DWN2KB]1697
Failure Code [DWN2KY]1699
Failure Code [DWN5KA]1700
Failure Code [DWN5KB]1702
Failure Code [DWN5KY]1703
Failure Code [DXA2KA]1705
Failure Code [DXA2KB]1707
Failure Code [DXA2KY]1709
Failure Code [DXH1KA]1710
Failure Code [DXH1KB]1712
Failure Code [DXH1KY]1714
Failure Code [DXH4KA]1716
Failure Code [DXH4KB]1718
Failure Code [DXH4KY]1720
Failure Code [DXH5KA]1722
Failure Code [DXH5KB]1724
Failure Code [DXH5KY]1726
Failure Code [DXH6KA]1728
Failure Code [DXH6KB]1730
Failure Code [DXH6KY]1732
Failure Code [DXH7KA]1734
Failure Code [DXH7KB]1736
Failure Code [DXH7KY]1738
Failure Code [DXH8KA]1740
Failure Code [DXH8KB]1742
Failure Code [DXH8KY]1744
Failure Code [DXJ4KA]1746
Failure Code [DXJ4KB]1748
Failure Code [F311KA]1750
Failure Code [F311KB]1752
Failure Code [F312KA]1754
Failure Code [F312KB]1756
Failure Code [F313KA]1758
Failure Code [F313KB]1760
Failure Code [F314KA]1763
Failure Code [F314KB]1765
Failure Code [F315KB]1767
Failure Code [F315KY]1769
Failure Code [F316KB]1771
Failure Code [F316KY]1773
Failure Code [F318KB]1775
Failure Code [F318KY]1778
Failure Code [F31AKB]1780
Failure Code [F31AKY]1782
Failure Code [F31BKB]1784
Failure Code [F31BKY]1786
Failure Code [F31CKB]1788
Failure Code [F31CKY]1790
Failure Code [F31DKB]1792
Failure Code [F31DKY]1794
Failure Code [F31EKB]1796
Failure Code [F31EKY]1798
Failure Code [FS10ZE]1800
Troubleshooting of Electrical System (E-Mode)1801
Engine Does Not Start (Engine Does Not Crank)1801
Manual Preheating System Does Not Operate1808
Automatic Preheating System Does Not Operate1811
While Preheating is in Operation, Preheating Monitor Does Not Come On1813
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1815
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On1819
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation1820
Charge Level Monitor Comes On in Red While Engine is in Operation1821
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1823
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation1824
Power Train Oil Temperature Monitor Comes On in Red While Engine Runs1825
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1826
Engine Coolant Temperature Gauge Does Not Show Correct Temperature1827
DEF Level is Not Shown Correctly1828
Fuel Gauge Does Not Show Normally1831
Power Train Oil Temperature Gauge Does Not Show Correct Temperature1833
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature1834
Operation Mode Does Not Change1835
Gear Shift Mode Does Not Change1836
When You Operate Customize Switch Does Not Show Customize Screen1837
When You Change Setting on Customize Screen, Setting of Machine is Not Changed1838
Some Areas of Machine Monitor Screen are Not Shown1839
REVERSE Slow Mode Function Does Not Operate Correctly1840
Alarm Buzzer Does Not Operate or Does Not Stop Operation1841
Service Meter is Not Shown While Starting Switch is in OFF Position1842
Service Mode Cannot be Selected1843
Horn Does Not Sound1844
Horn Does Not Stop1846
Backup Alarm Does Not Sound1847
Backup Alarm Does Not Stop Operation1849
Headlamp Does Not Come On1850
Rear Lamp Does Not Come On1854
No Wiper Operates1857
Front Wiper Does Not Operate1861
Rear Wiper Does Not Operate1864
Left Door Wiper Does Not Operate1867
Right Door Wiper Does Not Operate1870
Front Washer Does Not Operate1873
Rear Washer Does Not Operate1875
Left Door Washer Does Not Operate1877
Right Door Washer Does Not Operate1879
KOMTRAX System Does Not Operate Correctly1881
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1882
Information Shown in Troubleshooting Table (H-Mode)1882
System Chart of Hydraulic and Mechanical Systems1883
Failure Mode and Cause Table1885
Machine Lacks Power (Drawbar Pull is Not Sufficient)1893
Machine Does Not Travel (at 2nd or 3rd Gear Speed)1895
Machine Does Not Move Off at All Gear Speeds1896
Machine Travels Only in One Direction, Forward or in Reverse1898
Large Time Lag is in Gear Shifting or Directional Change1899
Brake Does Not Work1901
Power Train Oil Overheats1902
Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor1904
Torque Converter Lockup Clutch Does Not Engage1905
Machine Cannot be Steered (Machine Does Not Turn Left or Right)1906
Steering Speed or Power is Not Sufficient1907
All Work Equipment Operate Slowly1908
All Work Equipment Do Not Operate1909
Blade Lift Speed or Power is Low1910
Blade Tilt Speed or Power is Low1911
Blade Angle Speed or Power is Low1912
Ripper Lift Speed or Power is Low1913
Hydraulic Drift of Blade Lift is Large1914
Hydraulic Drift of Tilted Blade is Large1915
Hydraulic Drift of Lifted Ripper is Large1916
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)1917
Unusual Noise is Heard from Around Fan1919
Troubleshooting of Engine (S-Mode)1920
Information Shown in Troubleshooting Table (S-Mode)1920
Engine Does Not Crank When Starting Switch is Turned to Start Position1921
Engine Cranks but No Exhaust Smoke Comes Out1922
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1923
Engine Startability is Unsatisfactory1925
Engine Does Not Pick Up Smoothly1927
Engine Stops During Operation1929
Engine Does Not Rotate Smoothly1931
Engine Lacks Power1932
KDPF Becomes Clogged in a Short Time1935
Engine Oil Consumption is Excessive1937
Engine Oil Becomes Dirty Quickly1938
Fuel Consumption is Excessive1939
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)1940
Engine Oil Pressure Drops1941
Fuel Mixes Into Engine Oil1943
Water Mixes Into Engine Oil (Milky)1944
Coolant Temperature Becomes Too High (Overheating)1945
Unusual Noise is Heard1947
Vibration is Excessive1948
Air Cannot be Bled from Fuel Circuit1949
Active Regeneration is Done Frequently1950
Active Regeneration Continues Long1952
White Smoke is Exhausted During Active Regeneration1953
DEF Consumption is Excessive1954
There is an Unusual Smell (Irritating Odor)1956
Foreign Materials Enter DEF (DEF Increases)1957
50 Disassembly and Assembly1959
Table of Contents1960
Precautions Before Work1966
Related Information on Disassembly and Assembly1967
How to Read This Manual1967
Coating Materials List1968
Special Tool List1973
Sketches of Special Tools1997
Engine and Cooling System2018
Remove and Install Supply Pump Assembly2018
How to Remove Supply Pump Assembly2018
How to Install Supply Pump Assembly2022
Remove and Install Injector Assembly2028
How to Remove Injector Assembly2029
How to Install Injector Assembly2036
Remove and Install Cylinder Head Assembly2048
How to Remove Cylinder Head Assembly2049
How to Install Cylinder Head Assembly2059
Remove and Install EGR Valve Assembly2076
Remove EGR Valve Assembly2076
Install EGR Valve Assembly2077
Remove and Install EGR Cooler Assembly2078
How to Remove EGR Cooler Assembly2078
How to Install EGR Cooler Assembly2079
Remove and Install Starter Assembly2081
Remove Starting Motor Assembly2081
Install Starting Motor Assembly2083
Remove and Install Alternator Belt2086
Remove Alternator Belt2086
Install Alternator Belt2087
Remove and Install Automatic Tensioner2089
Remove Automatic Tensioner2089
Install Automatic Tensioner2089
Remove and Install Expansion Tank Assembly2090
How to Remove Expansion Tank Assembly2090
How to Install Expansion Tank Assembly2094
Remove and Install Radiator Assembly2099
How to Remove Radiator Assembly2099
How to Install Radiator Assembly2102
Remove and Install Hydraulic Oil Cooler Assembly2107
How to Remove Hydraulic Oil Cooler Assembly2107
How to Install Hydraulic Oil Cooler Assembly2109
Remove and Install Aftercooler Assembly2113
Remove Aftercooler Assembly2113
Install Aftercooler Assembly2115
Remove and Install Power Train Oil Cooler Assembly2118
How to Remove Power Train Oil Cooler Assembly2118
How to Install Power Train Oil Cooler Assembly2120
Remove and Install Cooling Fan Drive Assembly2123
How to Remove Cooling Fan Drive Assembly2123
How to Install Cooling Fan Drive Assembly2125
Remove and Install Cooling Fan Motor Assembly2128
Remove Cooling Fan Motor Assembly2128
Install Cooling Fan Motor Assembly2130
Remove and Install Engine Assembly2132
How to Remove Engine Assembly2132
How to Install Engine Assembly2138
Remove and Install Engine Front Oil Seal2145
How to Remove Engine Front Oil Seal2145
How to Install Engine Front Oil Seal2147
Remove and Install Engine Rear Oil Seal2151
How to Remove Engine Rear Oil Seal2151
How to Install Engine Rear Oil Seal2155
Remove and Install Engine Hood Assembly2163
How to Remove Engine Hood Assembly2163
How to Install Engine Hood Assembly2167
Remove and Install Fuel Tank Assembly2172
Remove Fuel Tank Assembly2172
Install Fuel Tank Assembly2175
Remove and Install Fuel Tank Assembly (Trimming Dozer Specifications)2178
How to Remove Fuel Tank Assembly (Trimming Dozer Specifications)2178
How to Install Fuel Tank Assembly (Trimming Dozer Specifications)2183
Remove and Install DEF Tank Assembly2188
How to Remove DEF Tank Assembly2189
How to Install DEF Tank Assembly2193
Remove and Install DEF Tank Sensor Flange Assembly2197
How to Remove DEF Tank Sensor Flange Assembly2198
How to Install DEF Tank Sensor Flange Assembly2202
Remove and Install DEF Tank Sensor2209
Remove DEF Tank Sensor2209
Install DEF Tank Sensor2210
Remove and Install DEF Tank Strainer2217
Remove DEF Tank Strainer2217
Install DEF Tank Strainer2217
Remove and Install KDPF Assembly2218
How to Remove KDPF Assembly2218
How to Install KDPF Assembly2222
Disassemble and Assemble KDPF Assembly2226
Disassemble KDPF Assembly2226
Assemble KDPF Assembly2230
Remove and Install SCR Assembly2236
How to Remove SCR Assembly2236
How to Install SCR Assembly2238
Remove and Install KDPF and SCR Assembly2241
How to Remove KDPF and SCR Assembly2241
Install KDPF and SCR Assembly2248
Remove and Install KCCV Assembly2255
Remove KCCV Assembly2255
Install KCCV Assembly2257
Remove and Install DEF Mixing Tube2259
Remove DEF Mixing Tube2259
Install DEF Mixing Tube2262
Remove and Install DEF Injector2267
Remove DEF Injector2267
Install DEF Injector2270
Remove and Install DEF Pump2274
Remove DEF Pump2274
Install DEF Pump2277
Remove and Install DEF Hose2280
Remove DEF Hose2280
Install DEF Hose2285
Remove and Install Air Cleaner Assembly2290
Remove Air Cleaner Assembly2290
Install Air Cleaner Assembly2291
Remove and Install Air Conditioner Compressor Assembly2293
Remove Air Conditioner Compressor Assembly2293
How to Install Air Conditioner Compressor Assembly2295
Remove and Install Air Conditioner Condenser Assembly2298
How to Remove Air Conditioner Condenser Assembly2298
How to Install Air Conditioner Condenser Assembly2300
Power Train2302
Remove and Install Damper Assembly2302
How to Remove Damper Assembly2302
How to Install Damper Assembly2307
Remove and Install Power Train Unit Assembly2313
How to Remove Power Train Unit Assembly2313
How to Install Power Train Unit Assembly2318
Disconnect and Connect Power Train Unit Assembly2324
How to Disconnect Power Train Unit Assembly2324
Connect Power Train Unit Assembly2329
Disassemble and Assemble PTO Assembly2335
Disassemble PTO Assembly2335
Assemble PTO Assembly2338
Disassemble and Assemble Torque Converter Assembly2342
Disassemble Torque Converter Assembly2343
Assemble Torque Converter Assembly2349
Disassemble and Assemble Transmission Assembly2358
Disassemble Transmission Assembly2359
Assemble Transmission Assembly2377
Disassemble and Assemble HSS Assembly2390
Disassemble HSS Assembly2392
Assemble HSS Assembly2403
Remove and Install HSS Motor Assembly2420
How to Remove HSS Motor Assembly2420
How to Install HSS Motor Assembly2422
Remove and Install Final Drive Assembly2425
How to Remove Final Drive Assembly2425
How to Install Final Drive Assembly2428
Disassemble and Assemble Final Drive Assembly2431
Disassemble Final Drive Assembly2432
Assemble Final Drive Assembly2437
Disassemble and Assemble Final Drive Assembly (Trimming Dozer Specifications)2445
How to Disassemble Final Drive Assembly (Trimming Dozer Specifications)2447
How to Assemble Final Drive Assembly (Trimming Dozer Specifications)2454
Undercarriage and Frame2464
Remove and Install Track Frame Assembly2464
Remove Track Frame Assembly2464
How to Install Track Frame Assembly2467
Remove and Install Idler Assembly2471
Remove Idler Assembly2471
Install Idler Assembly2472
Disassemble and Assemble Idler Assembly2474
Disassemble Idler Assembly2474
Assemble Idler Assembly2476
Remove and Install Recoil Spring Assembly2480
Remove Recoil Spring Assembly2480
Install Recoil Spring Assembly2480
Disassemble and Assemble Recoil Spring Assembly2482
Disassemble Recoil Spring Assembly2482
Assemble Recoil Spring Assembly2485
Remove and Install Track Roller Assembly2488
Remove Track Roller Assembly2488
How to Install Track Roller Assembly2488
Disassemble and Assemble Track Roller Assembly2490
Disassemble Track Roller Assembly2490
Assemble Track Roller Assembly2492
Remove and Install Carrier Roller Assembly2495
Remove Carrier Roller Assembly2495
Install Carrier Roller Assembly2496
Disassemble and Assemble Carrier Roller Assembly2497
Disassemble Carrier Roller Assembly2497
Assemble Carrier Roller Assembly2498
Remove and Install Pivot Shaft Assembly2501
How to Remove Pivot Shaft Assembly2501
How to Install Pivot Shaft Assembly2502
Separate and Connect Track Assembly2503
Examine Before Separation of Track Assembly2503
Separate Track Assembly (Standard)2503
How to Separate Track Assembly (When Track Frame Has Internal Defect)2504
Install Track Assembly2505
Separate and Connect PLUS Type Track Assembly2508
Separate PLUS Type Track Assembly Generally2508
Install PLUS Type Track Assembly2508
Disassemble and Assemble Track Assembly Generally2509
How to Disassemble Full Track Shoes Assembly2509
How to Assemble Full Track Shoes Assembly2512
Disassemble and Assemble PLUS Type Track Assembly Generally2524
Disassemble PLUS Type Track Assembly Generally2525
How to Assemble PLUS Type Track Shoes Assembly Generally2526
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)2541
Disassemble One Track Link Assembly in Field (Track Assembly)2542
Assemble One Track Link Assembly in Field (Track Assembly)2543
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2550
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly)2551
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)2553
Remove and Install Equalizer Bar Assembly2557
How to Remove Equalizer Bar Assembly2557
How to Install Equalizer Bar Assembly2559
Disassemble and Assemble Equalizer Bar Bushing2562
Disassemble Equalizer Bar Bushing2562
Assemble Equalizer Bar Bushing2562
Hydraulic System2564
Remove and Install Hydraulic Tank Assembly2564
How to Remove Hydraulic Tank Assembly2564
How to Install Hydraulic Tank Assembly2567
Remove and Install HSS Pump and Cooling Fan Pump Assembly2572
How to Remove HSS Pump and Cooling Fan Pump Assembly2572
How to Install HSS Pump and Cooling Fan Pump Assembly2574
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly2576
Remove Power Train Pump and Steering Lubrication Pump Assembly2576
Install Power Train Pump and Steering Lubrication Pump Assembly2578
Remove and Install Scavenging Pump Assembly2581
Remove Scavenging Pump Assembly2581
Install Scavenging Pump Assembly2581
Remove and Install 5 Spool Control Valve Assembly2583
How to Remove 5 Spool Control Valve Assembly2583
How to Install 5 Spool Control Valve Assembly2585
Remove and Install 4 Spool Control Valve Assembly2588
How to Remove 4 Spool Control Valve Assembly2588
How to Install 4 Spool Control Valve Assembly2591
Disassemble and Assemble Blade PPC Valve2594
How to Disassemble Blade PPC Valve2594
How to Assemble Blade PPC Valve2594
Disassemble and Assemble Ripper PPC Valve2596
How to Disassemble Ripper PPC Valve2596
How to Assemble Ripper PPC Valve2596
Work Equipment2598
Remove and Install Straight Tilt Power Pitch Dozer Blade Assembly2598
How to Remove Straight Tilt Power Pitch Dozer Blade Assembly2598
How to Install Straight Tilt Power Pitch Dozer Blade Assembly2600
Remove and Install Ripper Assembly2604
Remove Ripper Assembly2604
Install Ripper Assembly2607
How to Disassemble and Assemble Work Equipment Cylinder Assembly2610
How to Disassemble Work Equipment Cylinder Assembly2611
How to Assemble Work Equipment Cylinder Assembly2614
CAB Related Parts2619
Remove and Install Operator Cab Assembly2619
How to Remove Operator Cab Assembly2619
How to Install Operator Cab Assembly2627
Remove and Install Operator Cab Glass (Adhered Glass)2636
Remove Operator CAB Glass (Adhered Glass)2636
Install Operator CAB Glass (Adhered Glass)2637
Remove and Install Air Conditioner Unit Assembly2642
How to Remove Air Conditioner Unit Assembly2642
How to Install Air Conditioner Unit Assembly2648
Remove and Install Operator Seat2656
How to Remove Operator Seat2656
How to Install Operator Seat2658
How to Remove and Install Seat Belt2661
How to Remove Seat Belt2661
How to Install Seatbelt2662
Electrical System2663
Remove and Install Engine Controller Assembly2663
Remove Engine Controller Assembly2663
Install Engine Controller Assembly2664
Remove and Install Power Train Controller Assembly2667
Remove Power Train Controller Assembly2667
Install Power Train Controller Assembly2668
Remove and Install Machine Monitor Assembly2670
How to Remove Machine Monitor Assembly2670
How to Install Machine Monitor Assembly2671
Remove and Install Mass Air Flow and Temperature Sensor2673
How to Remove Mass Air Flow and Temperature Sensor2673
How to Install Mass Air Flow and Temperature Sensor2674
Remove and Install KCCV Crankcase Pressure Sensor2675
How to Remove KCCV Crankcase Pressure Sensor2675
How to Install KCCV Crankcase Pressure Sensor2676
Remove and Install SCR Temperature Sensor2677
Remove SCR Temperature Sensor2677
Install SCR Temperature Sensor2678
Remove and Install Rearview Camera2680
Remove Rearview Camera2680
Install Rearview Camera2680
Remove and Install KOMTRAX Terminal Assembly2682
How to Remove KOMTRAX Terminal Assembly2682
How to Install KOMTRAX Terminal Assembly2683
Remove and Install Gateway Function Controller Assembly2686
How to Remove Gateway Function Controller Assembly2686
How to Install Gateway Function Controller Assembly2689
Remove and Install Communication Terminal2694
How to Remove Communication Terminal2694
How to Install Communication Terminal2697
60 Maintenance Standard2701
Table of Contents2702
Explanation of Terms for Maintenance Standard2704
Engine and Cooling System2706
Maintenance Standard for Engine Mount2706
Maintenance Standard for Damper2707
Maintenance Standard for Cooling System2709
Maintenance Standard for Cooling Fan Pump2711
Maintenance Standard for Servo Valve2712
Maintenance Standard for Cooling Fan Motor2713
Power Train2715
Maintenance Standard for Universal Joint2715
Maintenance Standard for Power Train Mount2716
Maintenance Standard for Torque Converter and PTO2718
Maintenance Standard for Lockup Clutch ECMV2721
Maintenance Standard for Transmission2722
Maintenance Standard for Transmission Control Valve2727
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV2728
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve2729
Maintenance Standard for Transmission Lubrication Relief Valve2730
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake2731
Maintenance Standard for Brake Valve2736
Maintenance Standard for Final Drive2738
Maintenance Standard for Sprocket for Conventional Type Track Shoes2740
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes2741
Maintenance Standard for Sprocket for PLUS Type Track Shoes2743
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes2744
Undercarriage and Frame2746
Maintenance Standard for Main Frame2746
Maintenance Standard for Suspension2747
Maintenance Standard for Track Frame and Idler Cushion2749
Maintenance Standard for Idler2751
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type)2753
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type)2754
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)2755
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)2756
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes2757
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes2758
Maintenance Standard for Conventional Type Track Shoes2759
Maintenance Standard for PLUS Type Track Shoes2761
Maintenance Standard for Single Shoes2763
Maintenance Standard for Swamp Shoes2764
Hydraulic System2765
Maintenance Standard for Hydraulic Tank2765
Maintenance Standard for Scavenging Pump2766
Maintenance Standard for Steering Lubrication Pump and Power Train Pump2767
Maintenance Standard for Work Equipment and HSS Pump2768
Maintenance Standard for PC-EPC Valve2769
Maintenance Standard for HSS Motor2770
Maintenance Standard for Control Valve2772
Maintenance Standard for Blade PPC Valve2780
Maintenance Standard for Ripper PPC Valve2782
Maintenance Standard for Quick Drop Valve2784
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer and Angle Dozer Series)2786
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Tilt Pitch Dozer Series)2787
Work Equipment2788
Maintenance Standard for Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series)2788
Maintenance Standard for Front Work Equipment (Angle Dozer Series)2791
Maintenance Standard for Front Work Equipment (Trimming Dozer Specification)2794
Maintenance Standard for Cutting Edge and End Bit2796
Maintenance Standard for Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series)2798
Maintenance Standard for Blade Lift Cylinder (Trimming Dozer Specification)2799
Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series)2800
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series)2801
Maintenance Standard for Trimming Cylinder (Trimming Dozer Specification)2802
Maintenance Standard for Fixed Multi-Shank Ripper2803
Maintenance Standard for Ripper Lift Cylinder2804
CAB Related Parts2805
Maintenance Standard for CAB Mount2805
80 Appendix2807
Table of Contents2808
Precautions Before Work2810
Air Conditioner System2811
Precautions for Refrigerant2811
Air Conditioner Component2812
Specifications of Air Conditioner2814
Structure and Function of Refrigeration Cycle2815
Outline of Refrigeration Cycle2816
Component Parts of Air Conditioner System2818
Air Conditioner Unit2818
Configuration Diagram of Air Conditioner Unit2818
Function of Air Conditioner Unit2820
Component Parts of Air Conditioner Unit2822
Function of Evaporator as Air Conditioner Unit Component2823
Function of Heater Core as Air Conditioner Unit Component2823
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2823
Function of Servo Motor as Air Conditioner Unit Component2823
Structure of Expansion Valve as Air Conditioner Unit Component2824
Function of Expansion Valve as Air Conditioner Unit Component2824
Operate Expansion Valve as Air Conditioner Unit Component2824
Function of Dual Pressure Switch2825
Air Conditioner Controller2826
Structure of Air Conditioner Controller2826
Compressor2827
Structure of Compressor2827
Specifications of Compressor2827
Function of Compressor2827
Condenser2828
Structure of Standard Core Condenser2828
Specifications of Standard Core Condenser2828
Function of Standard Core Condenser2828
Structure of Wide Core Condenser2829
Specifications of Wide Core Condenser2829
Function of Wide Core Condenser2829
Receiver Drier2830
Structure of Receiver Dryer2830
Specifications of Receiver Dryer2830
Function of Receiver Dryer2830
Air Conditioner Related Sensors2831
Structure of Sunlight Sensor2831
Function of Sunlight Sensor2831
Structure of Outside Temperature Sensor2831
Function of Outside Air Temperature Sensor2831
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2833
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2835
System Diagram of Air Conditioner2837
Input and Output Signals of Air Conditioner Controller2838
Function of Air Conditioner Controller2839
Locations of Air Conditioner Parts and Layout of Connectors2840
Examine Air Leakage (Duct)2849
How to Examine Air Leakage (Duct)2849
Explanation for Test of Air Conditioner with Self-Diagnosis Function2852
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2853
Examine Vent (Mode) Changeover2854
How to Examine Vent (Mode) Changeover2854
Examine Fresh/Recirc Air Changeover2855
How to Examine Fresh/Recirc Air Changeover2855
Examine Sunlight Sensor2856
How to Examine Sunlight Sensor2856
Examine Refrigerant (Dual) Pressure Switch2857
How to Examine Refrigerant (Dual) Pressure Switch2857
Examine Relay2858
How to Examine Relay2858
Air Conditioner Troubleshooting Chart 12859
Air Conditioner Troubleshooting Chart 22860
Information Shown in Troubleshooting Table2863
Failure Code [879AKA]2864
Failure Code [879AKB]2865
Failure Code [879BKA]2866
Failure Code [879BKB]2868
Failure Code [879CKA]2870
Failure Code [879CKB]2871
Failure Code [879DKZ]2872
Failure Code [879EMC]2874
Failure Code [879FMC]2875
Failure Code [879GKX]2876
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2878
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2880
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2884
Troubleshooting for Fresh/Recirc Air Changeover2886
Troubleshooting by Gauge Pressure2888
Connect Service Tool2891
How to Connect Service Tool2891
Precautions for Disconnection and Connection of Air Conditioner Piping2893
Handle Compressor Oil2895
90 Circuit Diagrams2897
Table of Contents2898
How to Read the Codes for Electric Cable2899
Hydraulic Circuit Diagram2903
Symbols Used in Hydraulic Circuit Diagram2903
Hydraulic Circuit Diagram2907
Power Train Hydraulic Circuit Diagram2909
Electrical Circuit Diagram2911
Symbols Used in Electric Circuit Diagram2911
Electrical Circuit Diagram (1/13)2915
Electrical Circuit Diagram (2/13)2917
Electrical Circuit Diagram (3/13)2919
Electrical Circuit Diagram (4/13)2921
Electrical Circuit Diagram (5/13)2923
Electrical Circuit Diagram (6/13)2925
Electrical Circuit Diagram (7/13)2927
Electrical Circuit Diagram (8/13)2929
Electrical Circuit Diagram (9/13)2931
Electrical Circuit Diagram (10/13)2933
Electrical Circuit Diagram (11/13)2935
Electrical Circuit Diagram (12/13)2937
Electrical Circuit Diagram (13/13)2939
INDEX2941
S.M 28/12/24
