Komatsu Bulldozer D65PXi-18 Shop Manual SEN06620-12 PDF

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Komatsu Bulldozer D65PXi-18 Shop Manual SEN06620-12 –  PDF DOWNLOAD

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Komatsu Bulldozer D65PXi-18 Shop Manual SEN06620-12 –  PDF DOWNLOAD

Language : English
Pages : 3412
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer D65PXi-18 Shop Manual SEN06620-12 –  PDF DOWNLOAD

• SERIAL NUMBERS  90023 and up

Cover 1
00 Index and Foreword . 3
Index . 4
Abbreviation List . 25
Foreword, Safety, Basic Information . 31
How to Read the Shop Manual . 31
Safety Notice for Operation . 33
Precautions to Prevent Fire . 41
Procedures If Fire Occurs . 43
Precautions When You Discard Waste Materials 44
Procedures for Exhaust Gas Regulations 45
Precautions for DEF . 46
General Character and Precautions for Handling 46
Precautions When You Add 46
Precautions for Storage . 46
Precautions for Fire Hazard and Leakage . 46
Other Precautions . 46
Store DEF . 47
Precautions When You Handle Hydraulic Equipment . 48
Precautions When You Disconnect and Connect Pipings . 51
Precautions When You Handle Electrical Equipment 58
Precautions When You Handle Fuel System Equipment . 60
Precautions When You Handle Intake System Equipment . 61
Practical Use of KOMTRAX 62
Disconnect and Connect Push-Pull Type Coupler . 63
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 63
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 64
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 65
Precautions for Disconnection and Connection of Connectors 67
Disconnect and Connect Deutsch Connector 71
How to Disconnect and Connect Slide Lock Type Connector . 72
Disconnect and Connect Connector with Lock to Pull 74
Disconnect and Connect Connector with Lock to Push 75
Disconnect and Connect Connector with Housing to Rotate . 77
How to Read the Codes for Electric Cable 78
Explanation of Terms for Maintenance Standard . 82
Standard Tightening Torque Table 85
Conversion Table 92
01 Specification 97
Table of Contents . 98
Abbreviation List . 99
Specifications 105
Specification Drawing . 105
Specification Drawing: D65PXI-18 105
Specifications 107
Specifications: D65PXI-18 . 107
Weight Table 112
Weight Table: D65PXI-18 . 112
Table of Fuel, Coolant, and Lubricants 114
10 Structure and Function . 117
Table of Contents . 118
Abbreviation List . 122
Urea SCR System . 128
Layout Drawing of Urea SCR System . 128
Urea SCR System Diagram . 130
Function of Urea SCR System . 131
Function of DEF System(APPLICABLE MACHINE: 90023 to 96348) 131
FUNCTION OF DEF SYSTEM(APPLICABLE MACHINE: 96349 and up) 133
Inducement Strategy . 134
Component Parts of Urea SCR System 149
DEF Mixing Tube . 149
SCR Assembly 150
DEF Tank 152
DEF Pump 154
DEF Injector 156
DEF Hose 157
DEF Tank Heating Valve 158
Boot-up System 159
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 159
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) . 161
System Operating Lamp System 163
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 163
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) . 163
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 164
Function of System Operating Lamp System (Machine with Gateway Function Controller) . 164
Battery Disconnect Switch . 166
Layout Drawing of Battery Disconnect Switch . 166
Function of Battery Disconnect Switch . 166
Engine System . 168
Layout Drawing of Engine System . 168
Engine Control System . 170
Layout of Engine Control System (Machine with KOMTRAX Terminal) . 170
Layout of Engine Control System (Machine with Gateway Function Controller) 172
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) . 173
System Diagram of Engine Control System (Machine with Gateway Function Controller) 175
Function of Engine Control System (Machine with KOMTRAX Terminal) . 177
Function of Engine Control System (Machine with Gateway Function Controller) 179
Automatic Idle Stop System 181
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 181
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) . 182
Function of Automatic Idle Stop System 182
Component Parts of Engine System 185
Damper 185
VGT . 187
EGR System 191
EGR Valve . 193
EGR Cooler 195
KCCV System . 197
KCCV Ventilator . 199
KDPF 201
Cooling System 205
Layout Drawing of Cooling System 205
Specifications of Cooling System 206
Cooling Fan Control System 207
System Diagram of Cooling Fan Control System 207
Function of Cooling Fan Control System 208
Component Parts of Cooling System . 210
Cooling Fan Pump 210
Cooling Fan Motor . 219
Hydraulic Oil Cooler Bypass Valve . 226
Control System 227
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 227
Layout Drawing of Control System (Machine with Gateway Function Controller) . 228
Machine Monitor System 229
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 229
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) . 230
Function of Machine Monitor System 230
KOMTRAX System 231
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 231
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) . 231
Function of KOMTRAX System 232
Component Parts of Control System . 233
Machine Monitor . 233
KOMTRAX Terminal 249
Gateway Function Controller . 251
Communication Terminal 254
Power Train Controller 256
Engine Controller . 260
Hydraulic System 267
Layout Drawing of Hydraulic System 267
CLSS 268
Structure of CLSS . 268
Function of CLSS 269
Component Parts of Hydraulic System . 271
Hydraulic Tank 271
Work Equipment and HSS Pump . 273
LS Valve 279
PC Valve 284
PC-EPC Valve 289
Control Valve . 292
Power Train System 325
Layout Drawing of Power Train System 325
Operation of Power Train System . 327
Transmission, Steering, and Brake Control . 328
Layout Drawing of Transmission, Steering, and Brake Control System 328
Function of Transmission, Steering, and Brake Control . 329
Palm Command Control System . 330
Palm Command Control System Diagram . 330
HSS System 334
HSS System Diagram 334
Function of HSS System 335
Centralized Pressure Pickup Port 337
Layout Drawing of Centralized Pressure Pickup Port 337
Function of Centralized Pressure Pickup Port 337
Component Parts of Power Train System . 338
Universal Joint . 338
Power Train Mount . 339
Torque Converter and PTO 340
Lockup Clutch ECMV 346
Transmission 349
Transmission Control Valve 361
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 363
Main Relief Valve and Torque Converter Relief Valve . 368
Transmission Lubrication Relief Valve . 370
Bevel Gear Shaft, HSS, and Brake 371
Brake Valve . 390
Final Drive . 400
Scavenging Pump . 404
Steering Lubrication Pump and Power Train Pump 405
HSS Motor . 406
Electric Steering Electric Lever 412
Work Equipment System . 415
Work Equipment Control 415
Layout Drawing of Work Equipment Control 415
Function of Work Equipment Control 416
Layout of Tilt Dozer and Power Tilt Pitch Dozer Series 417
Component Parts of Work Equipment System 418
Self-Pressure Reducing Valve 418
Work Equipment Lock Solenoid Valve 424
Blade PPC Valve . 426
Pilot Circuit Accumulator . 432
Quick Drop Valve 433
Piston Valve 435
PPC Cut Solenoid Valve 437
ICT System 438
Layout Drawing of ICT System 438
System Diagram of ICT Control System 441
Blade Control System 443
Function of Blade Control System 443
Leveling Mode System Diagram 445
Function of Leveling Mode . 446
Operation of Leveling Mode 446
Dozing Mode System Diagram 447
Function of Dozing Mode . 448
Operation of Dozing Mode 448
Smooth Start System . 449
Smooth Start System Diagram . 449
Function of Smooth Start System . 449
Operation of Smooth Start System 450
Slip Control System . 451
Slip Control System Diagram . 451
Function of Slip Control System . 452
Operation of Slip Control System 452
Assist Control System . 453
Assist Control System Diagram . 453
Function of Assist Control System . 453
Operation of Assist Control System 454
Component Parts of ICT System . 455
ICT Sensor Controller . 455
Control Box . 459
GNSS Receiver . 462
GNSS Antenna 466
IMU Sensor 467
Cylinder EPC Valve Block Assembly . 471
Stroke and Reset Sensor for Blade Lift Cylinder . 475
Radio Control System 478
Layout Drawing of Radio Control System 478
Specifications of Radio Control System 479
Component Parts of Radio Control System . 480
Radio Control Transmitter . 480
Radio Control Receiver 482
Radio Control Controller 483
Undercarriage and Frame . 487
Main Frame 487
Structure of Main Frame . 487
Suspension 489
Structure of Suspension . 489
Specifications of Suspension 490
Function of Suspension 491
Track Frame and Idler Cushion . 492
Structure of Track Frame and Idler Cushion 492
Function of Track Frame and Idler Cushion . 493
Work Equipment 495
Structure of Front Work Equipment . 495
CAB Related Parts . 496
ROPS CAB 496
Structure of ROPS CAB (Machine with KOMTRAX Terminal) . 496
Structure of ROPS CAB (Machine with Gateway Function Controller) 497
Function of ROPS CAB 498
CAB Mount . 499
Structure of CAB Mount 499
Function of CAB Mount . 499
20 Standard Value Table . 501
Table of Contents . 502
Abbreviation List . 503
Standard Value Table for Engine . 509
Standard Value Table for Engine: D65PXI-18 509
Standard Value Table for Machine 514
Standard Value Table for Machine: D65PXI-18 . 514
Machine Posture and Procedures to Measure Performance . 529
Standard Value Table for Electricity 530
Standard Value Table for Electricity 530
30 Testing and Adjusting 539
Table of Contents . 540
Precautions Before Work . 544
Abbreviation List . 545
Related Information on Testing and Adjusting 551
Tools for Testing and Adjusting . 551
Sketch of Tools for Testing and Adjusting . 558
Engine and Cooling System . 561
Examine Engine Speed 561
How to Examine Engine Speed . 561
Examine Boost Pressure 565
How to Examine Boost Pressure . 565
Examine Exhaust Gas Temperature . 567
How to Examine Exhaust Gas Temperature 567
Examine Exhaust Gas Color . 569
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 569
How to Examine Exhaust Gas Color with Smoke Meter . 569
Examine Mass Air Flow and Temperature Sensor 571
How to Examine Mass Air Flow and Temperature Sensor . 571
Examine and Adjust Valve Clearance 573
Check Valve Clearance . 573
Adjust Valve Clearance 574
Examine Compression Pressure 576
How to Examine Compression Pressure . 576
Examine Blowby Pressure . 578
How to Examine Blowby Pressure 578
Examine Engine Oil Pressure . 581
How to Examine Engine Oil Pressure 581
Examine EGR Valve and VGT Oil Pressure 582
How to Examine EGR Valve and VGT Oil Pressure . 582
Examine Fuel Pressure . 584
How to Examine Fuel Pressure 585
Examine Fuel Discharge, Return and Leakage 591
How to Examine Fuel Discharge, Return, and Leakage 592
Bleed Air from Fuel System 596
How to Bleed Air from Fuel System . 596
Examine Fuel Circuit for Leakage 598
How to Examine Fuel System for Leakage 598
Handle Cylinder Cut-out Mode Operation 600
Handle No-Injection Cranking Operation 601
Examine and Adjust Air Conditioner Compressor Belt Tension 602
How to Examine Air Conditioner Compressor Belt Tension 602
How to Adjust Air Conditioner Compressor Belt Tension . 602
Examine Alternator Belt . 603
How to Examine Alternator Belt 603
Examine Automatic Tensioner . 604
How to Examine Automatic Tensioner 604
Write Correction for Ash in Soot Accumulation to Engine Controller 606
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 606
Examine SCR Related Functions . 607
Examine DEF Pump Raised Pressure 611
Examine Injection Volume from DEF Injector 614
Examine DEF Line Heater Relay 1 . 619
Examine DEF Line Heater Relay 2 . 622
Examine DEF Pump Heater Relay . 625
Examine DEF Tank Heater Valve . 628
Examine SCR Denitration Efficiency 631
Clean DEF Tank 634
How to Clean DEF Tank . 634
Clean DEF Tank Mounting Part 638
How to Clean DEF Tank Mounting Part . 638
Clean DEF Pump 640
How to Clean DEF Pump . 640
Adjust Decelerator Pedal 646
How to Adjust Decelerator Pedal . 646
Power Train . 648
Examine Power Train Oil Pressure 648
How to Examine Power Train Oil Pressure . 649
Adjust Transmission Output Shaft Speed Sensor . 660
How to Adjust Transmission Output Shaft Speed Sensor 660
Examine Brake Performance Simply 662
How to Examine Brake Performance Simply . 662
Adjust Brake Pedal 663
How to Adjust Brake Pedal . 663
Adjust Parking Brake Lever 666
How to Adjust Parking Brake Lever . 666
Move Machine by Parking Brake Release When Machine Does Not Travel 669
Move Machine with Hydraulic Type Parking Brake Release System . 669
Move Machine with Electric Type Parking Brake Release System 670
Undercarriage and Frame . 672
Adjust Idler Clearance 672
How to Adjust Idler Clearance . 672
Examine and Adjust Track Tension 673
How to Examine Track Tension 673
How to Adjust Track Tension . 673
Hydraulic System 674
Release Remained Pressure in Hydraulic Circuit 674
How to Release Remained Pressure in Hydraulic System 674
Examine and Adjust Work Equipment and HSS Oil Pressure 675
How to Examine Work Equipment and HSS Oil Pressure 675
Adjust Oil Pressure of Work Equipment and HSS . 678
Examine Oil Pressure of Control Circuit . 679
Examine Oil Pressure in Control Circuit . 679
Examine PPC Valve Outlet Pressure . 681
Examine Outlet Pressure in PPC Valve 681
Bleed Air from HSS Pump . 683
How to Bleed Air from HSS Pump 683
Examine and Adjust Play of Work Equipment PPC Valve . 684
How to Examine Play of Work Equipment PPC Valve . 684
How to Adjust Play of Work Equipment PPC Valve 685
Examine Cooling Fan Speed . 686
How to Examine Cooling Fan Speed 686
Examine Cooling Fan Circuit Oil Pressure 687
How to Examine Cooling Fan Circuit Oil Pressure . 687
Bleed Air in Cooling Fan Pump . 689
How to Bleed Air in Cooling Fan Pump 689
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 690
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder . 690
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder . 690
Examine Oil Leakage from Work Equipment Cylinder 692
How to Examine Internal Oil Leakage of Work Equipment Cylinder 692
Bleed Air from Work Equipment Cylinders . 694
Bleed Air from Work Equipment Cylinder 694
Work Equipment 695
Adjust Work Equipment Lock Lever 695
How to Adjust Work Equipment Lock Lever . 695
CAB Related Parts . 697
Examine and Adjust Operator Cab . 697
Examine Operator Cab 697
Adjust Operator Cab . 699
Electrical System . 702
Set and Operate Machine Monitor . 702
Operator Mode . 706
Function to Show Technician Identification Status Screen 706
Function to Show Operator Identification Input Screen . 706
Examine Function by LCD (Liquid Crystal Display) 707
Examine Function of Service Meter . 707
Usage Limitation and Change Maintenance Password 707
Service Mode 710
How to Operate Service Mode . 710
How to See Pre-defined Monitoring Information . 711
How to Examine Self-Define Monitor Information 718
Abnormality Record Menu . 730
How to See Maintenance Record . 734
Maintenance Mode Setting 735
Set Phone Number Entry 739
Default Menu 741
Diagnostic Tests Menu . 748
Adjustment Menu . 757
No-Injection Cranking Operation . 810
KOMTRAX Settings Menu . 812
Show Service Message 816
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) . 818
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 823
Start Up KOMTRAX System (Machine with Gateway Function Controller) 825
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) . 831
Adjust When Power Train Controller is Replaced 833
How to Adjust When Power Train Controller is Replaced . 833
Adjust Rearview Camera Angle 836
How to Adjust Rearview Camera Angle . 836
Handle Voltage Circuit of Engine Controller . 837
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 838
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) . 839
Examine Diodes 840
Examine Diodes by Digital Tester 840
How to Examine Diodes by Analog Tester 840
ICT System 841
Set and Operate Control Box . 841
Examine and Adjust ICT Related Devices (Straight Tilt Dozer) 842
Calibrate Blade Edge Position . 846
How to Operate Blade Calibration Menu (Pitch Rod Calibration) (Straight Tilt Dozer) . 847
How to Operate Blade Calibration Menu (Machine Cal Step A) (Straight Tilt Dozer) 849
How to Operate Blade Calibration Menu (Machine Cal Step B) (Straight Tilt Dozer) 853
Calibrate IMU Sensor 867
How to Calibrate IMU Sensor . 867
Reset Cylinder Stroke End (Straight Tilt Dozer) . 874
Set Standard Angle of Blade Edge 876
How to Input Wear Volume of Blade Edge and Track Shoes 878
Examine and Adjust Blade Elevation 879
Examine Blade Elevation (Straight Tilt Dozer) (For Old Control Box) . 879
Examine Blade Elevation (Straight Tilt Dozer) (For New Control Box) . 881
Adjust Blade Elevation (For Old Control Box) 884
Adjust Blade Elevation (For New Control Box) 885
Examine Stroke Sensor for Lift Cylinder . 887
How to Examine Stroke Sensor for Lift Cylinder (Straight Tilt Dozer) 887
Examine and Adjust Reset Sensor for Lift Cylinder . 891
How to Examine Reset Sensor for Lift Cylinder (Straight Tilt Dozer) . 891
How to Adjust Reset Sensor for Lift Cylinder (Straight Tilt Dozer) 892
Adjust When ICT Sensor Controller is Replaced . 893
How to Adjust When ICT Sensor Controller is Replaced (Straight Tilt Dozer) 893
Adjust When ICT Related Devices are Repaired or Replaced (Straight Tilt Dozer) 896
Radio Control . 900
ID Setup 900
How to Set Radio Control Transmitter ID . 900
How to Set Radio Control Receiver ID 901
Pm Clinic . 904
Pm Clinic Service . 904
Pm Clinic Check Sheet: D65PXI-18 906
Pm Clinic Check Sheet for Undercarriage: D65PXI-18 916
40 Troubleshooting 923
Table of Contents . 924
Precautions Before Work . 937
Abbreviation List . 938
Related Information to Troubleshooting 944
General Troubleshooting Points 944
Troubleshooting Points for Urea SCR System 945
Sequence of Events in Troubleshooting . 959
Troubleshooting for Radio Control System 961
Checks Before Troubleshooting (Specifications of Radio Control) . 961
Examine Operating State of Radio Control Receiver . 962
Examine Operating State of Radio Control Transmitter 963
Checks Before Troubleshooting . 964
Inspection Procedure Before Troubleshooting . 966
Walk-Around Check . 966
Test in Accordance with Testing Procedure . 968
How to Examine Electric Equipment . 968
Preparation for Troubleshooting of Electrical System 976
Procedure for Troubleshooting . 984
Symptom and Troubleshooting Numbers . 987
Information Shown in Troubleshooting Table 992
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 994
Connector List and Layout . 996
Connector Contact Connection Table 1016
T-Branch Box and T-Branch Adapter Table .1056
Fuse Location Table .1062
Precautions When You Clean and Replace KDPF (KCSF and KDOC) .1065
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1069
Failure Code Table 1071
Troubleshooting by Failure Code (Display of Code) .1096
Failure Code [1500L0] .1096
Failure Code [15SAL1] .1097
Failure Code [15SALH] .1099
Failure Code [15SBL1] .1101
Failure Code [15SBLH] .1103
Failure Code [15SEL1] .1105
Failure Code [15SELH] .1107
Failure Code [15SFL1] .1109
Failure Code [15SFLH] .1111
Failure Code [15SGL1] .1113
Failure Code [15SGLH] .1115
Failure Code [15SJL1] .1117
Failure Code [15SJLH] .1119
Failure Code [1800MW] .1121
Failure Code [2301L1] .1122
Failure Code [2301LH] .1124
Failure Code [2302L1] .1126
Failure Code [2302LH] .1128
Failure Code [7RFAKA] .1130
Failure Code [7RFAKB] .1132
Failure Code [7RFAKY] .1134
Failure Code [8512KX] .1136
Failure Code [8513KX] .1137
Failure Code [8514KX] .1138
Failure Code [8515KX] .1139
Failure Code [8516KX] .1140
Failure Code [8517KX] .1141
Failure Code [8518KX] .1142
Failure Code [8519KX] .1143
Failure Code [851AKX] .1144
Failure Code [851BKX] .1145
Failure Code [851CKX] .1146
Failure Code [851DKX] .1147
Failure Code [851EKX] .1148
Failure Code [851FKX] .1149
Failure Code [851GKX] .1150
Failure Code [851HKX] .1151
Failure Code [851JKX] .1152
Failure Code [851KKX] .1153
Failure Code [851LKX] .1154
Failure Code [851MKX] .1155
Failure Code [851NKX] .1156
Failure Code [8580MC] .1157
Failure Code [8581KK] .1158
Failure Code [8582KK] .1160
Failure Code [858LKA] .1162
Failure Code [858LKB] .1164
Failure Code [858QKR] .1166
Failure Code [858RKR] .1167
Failure Code [879AKA] .1168
Failure Code [879AKB] .1169
Failure Code [879BKA] .1170
Failure Code [879BKB] .1172
Failure Code [879CKA] .1174
Failure Code [879CKB] .1175
Failure Code [879DKZ] .1176
Failure Code [879EMC] .1178
Failure Code [879FMC] .1179
Failure Code [879GKX] .1180
Failure Code [989L00] .1182
Failure Code [989M00] .1183
Failure Code [989N00] .1184
Failure Code [A1U0N3] .1185
Failure Code [A1U0N4] .1187
Failure Code [A900FR] .1189
Failure Code [A900N6] .1190
Failure Code [A900NY] .1191
Failure Code [AA10NX] .1192
Failure Code [AB00KE] .1194
Failure Code [AQ10N3] .1196
Failure Code [AS00N3] .1198
Failure Code [AS00R2] .1200
Failure Code [AS00R3] .1201
Failure Code [AS00R4] .1202
Failure Code [AS00R5] .1203
Failure Code [AS00R6] .1204
Failure Code [AS00ZK] .1205
Failure Code [AS10KM] .1206
Failure Code [AS10NR] .1207
Failure Code [AS10NT] .1208
Failure Code [B@BAZG] .1209
Failure Code [B@BCNS] .1210
Failure Code [B@CENS] .1211
Failure Code [B@HANS] .1212
Failure Code [CA115] 1213
Failure Code [CA122] 1214
Failure Code [CA123] 1216
Failure Code [CA131] 1218
Failure Code [CA132] 1220
Failure Code [CA144] 1223
Failure Code [CA145] 1225
Failure Code [CA153] 1227
Failure Code [CA154] 1230
Failure Code [CA187] 1233
Failure Code [CA221] 1235
Failure Code [CA222] 1237
Failure Code [CA227] 1239
Failure Code [CA234] 1240
Failure Code [CA238] 1241
Failure Code [CA239] 1243
Failure Code [CA249] 1245
Failure Code [CA256] 1247
Failure Code [CA271] 1249
Failure Code [CA272] 1251
Failure Code [CA281] 1253
Failure Code [CA322] 1254
Failure Code [CA323] 1256
Failure Code [CA324] 1258
Failure Code [CA325] 1260
Failure Code [CA331] 1262
Failure Code [CA332] 1264
Failure Code [CA343] 1266
Failure Code [CA351] 1267
Failure Code [CA352] 1268
Failure Code [CA356] 1271
Failure Code [CA357] 1273
Failure Code [CA386] 1275
Failure Code [CA428] 1276
Failure Code [CA429] 1278
Failure Code [CA435] 1280
Failure Code [CA441] 1282
Failure Code [CA442] 1284
Failure Code [CA449] 1285
Failure Code [CA451] 1289
Failure Code [CA452] 1292
Failure Code [CA488] 1294
Failure Code [CA515] 1295
Failure Code [CA516] 1297
Failure Code [CA553] 1299
Failure Code [CA555] 1300
Failure Code [CA556] 1301
Failure Code [CA559] 1302
Failure Code [CA595] 1306
Failure Code [CA687] 1307
Failure Code [CA689] 1309
Failure Code [CA691] 1314
Failure Code [CA692] 1316
Failure Code [CA697] 1318
Failure Code [CA698] 1319
Failure Code [CA731] 1320
Failure Code [CA778] 1322
Failure Code [CA1117] .1327
Failure Code [CA1664] .1328
Failure Code [CA1669] .1331
Failure Code [CA1673] .1332
Failure Code [CA1677] .1333
Failure Code [CA1678] .1334
Failure Code [CA1682] .1335
Failure Code [CA1683] .1340
Failure Code [CA1684] .1342
Failure Code [CA1686] .1344
Failure Code [CA1691] .1345
Failure Code [CA1694] .1348
Failure Code [CA1695] .1351
Failure Code [CA1696] .1352
Failure Code [CA1712] .1354
Failure Code [CA1713] .1357
Failure Code [CA1714] .1359
Failure Code [CA1715] .1360
Failure Code [CA1776] .1361
Failure Code [CA1777] .1364
Failure Code [CA1843] .1367
Failure Code [CA1844] .1369
Failure Code [CA1879] .1372
Failure Code [CA1881] .1375
Failure Code [CA1883] .1378
Failure Code [CA1885] .1382
Failure Code [CA1887] .1384
Failure Code [CA1921] .1386
Failure Code [CA1922] .1389
Failure Code [CA1942] .1394
Failure Code [CA1993] .1395
Failure Code [CA2185] .1398
Failure Code [CA2186] .1400
Failure Code [CA2249] .1402
Failure Code [CA2265] .1403
Failure Code [CA2266] .1405
Failure Code [CA2271] .1407
Failure Code [CA2272] .1410
Failure Code [CA2288] .1413
Failure Code [CA2311] .1414
Failure Code [CA2349] .1415
Failure Code [CA2353] .1418
Failure Code [CA2357] .1420
Failure Code [CA2381] .1421
Failure Code [CA2382] .1424
Failure Code [CA2383] .1427
Failure Code [CA2386] .1430
Failure Code [CA2387] .1432
Troubleshooting Flowchart .1436
Failure Code [CA2555] .1437
Failure Code [CA2556] .1440
Failure Code [CA2637] .1443
Failure Code [CA2639] .1445
Failure Code [CA2771] .1448
Failure Code [CA2777] .1454
Failure Code [CA2976] .1457
Failure Code [CA3133] .1459
Failure Code [CA3134] .1461
Failure Code [CA3135] .1463
Failure Code [CA3142] .1467
Failure Code [CA3143] .1468
Failure Code [CA3144] .1469
Failure Code [CA3146] .1471
Failure Code [CA3147] .1472
Failure Code [CA3148] .1473
Failure Code [CA3151] .1475
Failure Code [CA3165] .1481
Failure Code [CA3229] .1483
Failure Code [CA3231] .1485
Failure Code [CA3232] .1487
Failure Code [CA3235] .1491
Failure Code [CA3239] .1493
Failure Code [CA3241] .1496
Failure Code [CA3242] .1499
Failure Code [CA3251] .1502
Failure Code [CA3253] .1504
Failure Code [CA3254] .1507
Failure Code [CA3255] .1510
Failure Code [CA3256] .1513
Failure Code [CA3311] .1515
Failure Code [CA3312] .1517
Failure Code [CA3313] .1520
Failure Code [CA3314] .1521
Failure Code [CA3315] .1522
Failure Code [CA3316] .1525
Failure Code [CA3317] .1526
Failure Code [CA3318] .1527
Failure Code [CA3319] .1530
Failure Code [CA3321] .1531
Failure Code [CA3322] .1533
Failure Code [CA3419] .1536
Failure Code [CA3421] .1538
Failure Code [CA3497] .1540
Failure Code [CA3498] .1541
Failure Code [CA3543] .1542
Failure Code [CA3545] .1549
Failure Code [CA3547] .1551
Failure Code [CA3558] .1552
Failure Code [CA3559] .1554
Failure Code [CA3562] .1556
Failure Code [CA3563] .1558
Failure Code [CA3567] .1561
Failure Code [CA3568] .1564
Failure Code [CA3571] .1570
Failure Code [CA3572] .1572
Failure Code [CA3574] .1574
Failure Code [CA3575] .1577
Failure Code [CA3577] .1579
Failure Code [CA3578] .1581
Failure Code [CA3582] .1583
Failure Code [CA3583] .1592
Failure Code [CA3596] .1594
Failure Code [CA3649] .1597
Failure Code [CA3681] .1599
Failure Code [CA3682] .1601
Failure Code [CA3713] .1604
Failure Code [CA3717] .1607
Failure Code [CA3718] .1608
Failure Code [CA3725] .1609
Failure Code [CA3741] .1612
Failure Code [CA3748] .1613
Failure Code [CA3751] .1616
Failure Code [CA3755] .1618
Failure Code [CA3866] .1620
Failure Code [CA3867] .1624
Failure Code [CA3868] .1627
Failure Code [CA3899] .1631
Failure Code [CA3911] .1633
Failure Code [CA3912] .1637
Failure Code [CA3932] .1639
Failure Code [CA3933] .1641
Failure Code [CA3934] .1643
Failure Code [CA3935] .1646
Failure Code [CA3936] .1648
Failure Code [CA4151] .1650
Failure Code [CA4152] .1654
Failure Code [CA4155] .1658
Failure Code [CA4156] .1661
Failure Code [CA4157] .1664
Failure Code [CA4158] .1666
Failure Code [CA4159] .1667
Failure Code [CA4161] .1668
Failure Code [CA4162] .1670
Failure Code [CA4163] .1673
Failure Code [CA4164] .1675
Failure Code [CA4165] .1677
Failure Code [CA4166] .1679
Failure Code [CA4168] .1681
Failure Code [CA4169] .1684
Failure Code [CA4171] .1686
Failure Code [CA4249] .1689
Failure Code [CA4251] .1691
Failure Code [CA4259] .1693
Failure Code [CA4261] .1696
Failure Code [CA4277] .1699
Failure Code [CA4281] .1703
Failure Code [CA4459] .1707
Failure Code [CA4461] .1710
Failure Code [CA4658] .1713
Failure Code [CA4731] .1717
Failure Code [CA4732] .1718
Failure Code [CA4739] .1719
Failure Code [CA4768] .1720
Failure Code [CA4769] .1722
Failure Code [CA4842] .1725
Failure Code [CA4952] .1729
Failure Code [CA5115] .1731
Failure Code [CA5383] .1734
Failure Code [D130KA] .1736
Failure Code [D130KB] .1739
Failure Code [D141KA] .1741
Failure Code [D141KB] .1743
Failure Code [D141KY] .1745
Failure Code [D162KA] .1747
Failure Code [D162KB] .1749
Failure Code [D162KY] .1751
Failure Code [D19CKA] .1753
Failure Code [D19CKB] .1755
Failure Code [D19CKY] .1757
Failure Code [D19DKA] .1759
Failure Code [D19DKB] .1761
Failure Code [D19DKY] .1763
Failure Code [D19EKA] .1765
Failure Code [D19EKB] .1767
Failure Code [D19EKY] .1769
Failure Code [D19FKA] .1771
Failure Code [D19FKB] .1773
Failure Code [D19FKY] .1775
Failure Code [D19GKA] .1777
Failure Code [D19GKB] .1779
Failure Code [D19GKY] .1781
Failure Code [D19JKZ] .1783
Failure Code [D811MC] .1786
Failure Code [D862KA] .1787
Failure Code [D8ALKA] .1788
Failure Code [D8ALKB] .1790
Failure Code [D8AQKR] .1792
Failure Code [DAF0MB] .1794
Failure Code [DAF0MC] .1795
Failure Code [DAF8KB] .1796
Failure Code [DAF9KQ] .1797
Failure Code [DAFGMC] .1798
Failure Code [DAFLKA] .1799
Failure Code [DAFLKB] .1801
Failure Code [DAFQKR] .1803
Failure Code [DAQW00] .1804
Failure Code [DAZ9KQ] .1805
Failure Code [DAZQKR] .1806
Failure Code [DB2QKR] .1807
Failure Code [DB2RKR] .1814
Failure Code [DBE0KT] .1820
Failure Code [DBE1KK] .1821
Failure Code [DBE2KK] .1824
Failure Code [DBE5KK] .1827
Failure Code [DBE6KK] .1829
Failure Code [DBE7KK] .1831
Failure Code [DBE9KQ] .1833
Failure Code [DBELKA] .1834
Failure Code [DBELKB] .1836
Failure Code [DBEQKR] .1838
Failure Code [DBERKR] .1839
Failure Code [DBR0KT] .1841
Failure Code [DBR0MC] .1842
Failure Code [DBR1KK] .1843
Failure Code [DBR2KK] .1846
Failure Code [DBR5KK] .1849
Failure Code [DBR7KK] .1851
Failure Code [DBRLKA] .1853
Failure Code [DBRLKB] .1855
Failure Code [DBRPMA] .1857
Failure Code [DBRQKR] .1858
Failure Code [DBRRKR] .1860
Failure Code [DBTSKR] .1861
Failure Code [DBUTKA] .1864
Failure Code [DD12KA] .1865
Failure Code [DD12KB] .1867
Failure Code [DD13KA] .1869
Failure Code [DD13KB] .1871
Failure Code [DD14KA] .1873
Failure Code [DD14KB] .1875
Failure Code [DDKFL4] .1877
Failure Code [DDKGL4] .1879
Failure Code [DDKHKA] .1881
Failure Code [DDKHKB] .1883
Failure Code [DDKQKA] .1885
Failure Code [DDKQKB] .1887
Failure Code [DDKRKA] .1889
Failure Code [DDKRKB] .1891
Failure Code [DDKSKA] .1893
Failure Code [DDKSKB] .1895
Failure Code [DDN7KA] .1897
Failure Code [DDN7KB] .1899
Failure Code [DDNLKA] .1901
Failure Code [DDNLKB] .1903
Failure Code [DGS1KA] .1905
Failure Code [DGS1KX] .1907
Failure Code [DGT1KA] .1909
Failure Code [DGT1KX] .1912
Failure Code [DH21KA] .1914
Failure Code [DH21KY] .1916
Failure Code [DHA4KA] .1918
Failure Code [DHAAMA] .1920
Failure Code [DHACMA] .1922
Failure Code [DHSKKA] .1924
Failure Code [DHSKKY] .1926
Failure Code [DHSLKA] .1928
Failure Code [DHSLKY] .1930
Failure Code [DHSWKA] .1932
Failure Code [DHSWKY] .1934
Failure Code [DHSXKA] .1936
Failure Code [DHSXKY] .1938
Failure Code [DHTDKA] .1940
Failure Code [DHTDKY] .1942
Failure Code [DK10KA] .1944
Failure Code [DK10KB] .1947
Failure Code [DK30KA] .1949
Failure Code [DK30KX] .1952
Failure Code [DK30KY] .1953
Failure Code [DK30KZ] .1955
Failure Code [DK30L8] .1956
Failure Code [DK31KA] .1957
Failure Code [DK31KY] .1960
Failure Code [DK40KA] .1962
Failure Code [DK40KY] .1964
Failure Code [DK55KX] .1966
Failure Code [DK55KZ] .1967
Failure Code [DK55L8] .1968
Failure Code [DK56KA] .1969
Failure Code [DK56KY] .1971
Failure Code [DK57KA] .1973
Failure Code [DK57KY] .1975
Failure Code [DK80KA] .1977
Failure Code [DKH1KA] .1980
Failure Code [DKH1KY] .1983
Failure Code [DKS0L8] .1985
Failure Code [DKS1KA] .1986
Failure Code [DKS1KB] .1988
Failure Code [DKS2KA] .1990
Failure Code [DKS2KB] .1992
Failure Code [DKS3KA] .1994
Failure Code [DKS3KB] .1996
Failure Code [DKS3MB] .1998
Failure Code [DKS4L8] .2000
Failure Code [DKS5KA] .2001
Failure Code [DKS5KB] .2003
Failure Code [DKS6KA] .2005
Failure Code [DKS6KB] .2007
Failure Code [DKS7MB] .2009
Failure Code [DKSCL8] .2010
Failure Code [DKSDKA] .2011
Failure Code [DKSDKB] .2013
Failure Code [DKSEKA] .2015
Failure Code [DKSEKB] .2017
Failure Code [DKSFMB] .2019
Failure Code [DKSGL8] .2020
Failure Code [DKSHKA] .2021
Failure Code [DKSHKB] .2023
Failure Code [DKSJKA] .2025
Failure Code [DKSJKB] .2027
Failure Code [DKSKKA] .2029
Failure Code [DKSKKB] .2031
Failure Code [DKSKMB] .2033
Failure Code [DKSLL8] .2035
Failure Code [DKSMKA] .2036
Failure Code [DKSMKB] .2038
Failure Code [DKSNKA] .2040
Failure Code [DKSNKB] .2042
Failure Code [DKSPKA] .2044
Failure Code [DKSPKB] .2046
Failure Code [DKSPMB] .2048
Failure Code [DLM3KA] .2050
Failure Code [DLM3MB] .2052
Failure Code [DLT3KA] .2053
Failure Code [DLT3KB] .2055
Failure Code [DR21KX] .2057
Failure Code [DR31KX] .2058
Failure Code [DUMCKB] .2059
Failure Code [DUMCKY] .2061
Failure Code [DV20KB] .2063
Failure Code [DW5AKA] .2065
Failure Code [DW5AKB] .2067
Failure Code [DW5AKY] .2069
Failure Code [DW7BKA] .2071
Failure Code [DW7BKB] .2073
Failure Code [DW7BKY] .2075
Failure Code [DWN1KA] .2076
Failure Code [DWN1KB] .2078
Failure Code [DWN1KY] .2080
Failure Code [DWN2KA] .2082
Failure Code [DWN2KB] .2084
Failure Code [DWN2KY] .2086
Failure Code [DWN3KA] .2087
Failure Code [DWN3KB] .2089
Failure Code [DWN3KY] .2091
Failure Code [DWN5KA] .2093
Failure Code [DWN5KB] .2095
Failure Code [DWN5KY] .2096
Failure Code [DXA2KA] .2098
Failure Code [DXA2KB] .2100
Failure Code [DXA2KY] .2102
Failure Code [DXECKA] .2103
Failure Code [DXECKB] .2105
Failure Code [DXECKY] .2107
Failure Code [DXH1KA] .2109
Failure Code [DXH1KB] .2111
Failure Code [DXH1KY] .2113
Failure Code [DXH4KA] .2115
Failure Code [DXH4KB] .2117
Failure Code [DXH4KY] .2119
Failure Code [DXH5KA] .2121
Failure Code [DXH5KB] .2123
Failure Code [DXH5KY] .2125
Failure Code [DXH6KA] .2127
Failure Code [DXH6KB] .2129
Failure Code [DXH6KY] .2131
Failure Code [DXH7KA] .2133
Failure Code [DXH7KB] .2135
Failure Code [DXH7KY] .2137
Failure Code [DXH8KA] .2139
Failure Code [DXH8KB] .2141
Failure Code [DXH8KY] .2143
Failure Code [DXHBKA] .2145
Failure Code [DXHBKB] .2147
Failure Code [DXHBKY] .2149
Failure Code [DXHCKA] .2151
Failure Code [DXHCKB] .2153
Failure Code [DXHCKY] .2155
Failure Code [DXHRKA] .2157
Failure Code [DXHRKB] .2159
Failure Code [DXHRKY] .2160
Failure Code [DXHSKA] .2162
Failure Code [DXHSKB] .2164
Failure Code [DXHSKY] .2165
Failure Code [DXHTKA] .2167
Failure Code [DXHTKB] .2169
Failure Code [DXHTKY] .2170
Failure Code [DXHUKA] .2171
Failure Code [DXHUKB] .2173
Failure Code [DXHUKY] .2174
Failure Code [DXJ4KA] .2175
Failure Code [DXJ4KB] .2177
Failure Code [DXJCKA] .2179
Failure Code [DXJCKB] .2181
Failure Code [DXJCKY] .2183
Failure Code [DXJDKA] .2185
Failure Code [DXJDKB] .2187
Failure Code [DXJDKY] .2189
Troubleshooting of Electrical System (E-Mode) .2191
Engine Does Not Start (Engine Does Not Crank) .2191
Engine Does Not Start in Radio Control Mode (Engine Does Not Crank) .2198
Engine Stops During Operation (Specifications of Radio Control) .2201
Manual Preheating System Does Not Operate .2205
Automatic Preheating System Does Not Operate 2208
While Preheating is in Operation, Preheating Monitor Does Not Come On .2210
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2212
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On .2216
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2217
Charge Level Monitor Comes On in Red While Engine is in Operation .2218
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .2220
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 2221
Power Train Oil Temperature Monitor Comes On in Red While Engine Runs .2222
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2223
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2224
DEF Level is Not Shown Correctly 2225
Fuel Gauge Does Not Show Normally .2228
Power Train Oil Temperature Gauge Does Not Show Correct Temperature .2230
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature .2231
Operation Mode Does Not Change 2232
Gear Shift Mode Does Not Change .2233
Movement of Machine Does Not Agree to Instructions in Radio Control Transmitter Operation .2234
Radio Control/On-board Can Not be Changed .2237
All Radio Control Can Not be Operated .2239
When You Operate Customize Switch Does Not Show Customize Screen 2241
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 2242
Some Areas of Machine Monitor Screen are Not Shown 2243
REVERSE Slow Mode Function Does Not Operate Correctly .2244
Alarm Buzzer Does Not Operate or Does Not Stop Operation 2245
Service Meter is Not Shown While Starting Switch is in OFF Position .2246
Service Mode Cannot be Selected .2247
Horn Does Not Sound .2248
Horn Does Not Stop 2250
Horn Does Not Operate or Does Not Stop (Specifications of Radio Control) 2251
Backup Alarm Does Not Sound .2253
Backup Alarm Does Not Stop Operation 2255
Headlamp Does Not Come On .2256
Rear Lamp Does Not Come On 2260
Working Lamp Does Not Come On or Go Out (Radio Control Specification) .2263
Red Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) .2267
Yellow Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2270
Blue Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2273
Green Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) .2276
No Wiper Operates .2279
Front Wiper Does Not Operate 2283
Rear Wiper Does Not Operate .2286
Left Door Wiper Does Not Operate 2289
Right Door Wiper Does Not Operate .2292
Gear Cannot be Shifted 2295
Front Washer Does Not Operate .2296
Rear Washer Does Not Operate 2298
Left Door Washer Does Not Operate .2300
Right Door Washer Does Not Operate 2302
KOMTRAX System Does Not Operate Correctly .2304
Control Box Shuts Down After It Shows Messages [GPS receiver not connected!] and [Slope sensor not connected!] 2305
Control Box Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !] 2309
Control Box Shows Message [Waiting for radio link .] .2312
Control Box Shows Message [IMU sensor not connected] Show Production 2313
Control Box Shows Message [Waiting for satellites .] .2314
Control Box Shows Message [GPS receiver not connected!] Show Production .2315
Control Box Shows Message [Cylinder Stroke Reading Abnormal] 2317
Control Box Shows Message [Komatsu CAN Comms Abnormal] 2318
Control Box Shows Message [Komatsu Machine Trouble] .2319
Control Box Shows Message [Waiting to initialize ] .2320
Control Box Shows Message [System initializing] .2321
Control Box Shows Message [Initializing ] 2322
Control Box Shows Message [Configuring GPS] .2323
Control Box Shows Message [No GPS Localization .] 2324
Control Box Shows Message [Low precisions .] .2325
Control Box Shows Message [Heading Initializing] 2326
Control Box Displays [Out of design area .] 2327
Control Box Can Not be Turned on 2328
Control Box Does Not Display Intelligent Machine Control Screen .2329
Control Box Does Not Display Bulldozer Image 2330
Control Box Does Not Display Design Surface .2331
Control Box Touch Panel Does Not Respond 2332
Control Box Touch Panel is Inaccurate .2333
Cylinder Stroke Reset Indication Does Not Go Out 2334
AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes off) 2335
Blade Automatic Lower Control Does Not Start While AUTO is Shown 2336
Blade Automatic Raise Control Does Not Start While AUTO is Shown 2337
Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops) .2338
When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine .2339
Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface) 2340
Finished Surface is Inaccurate (The Finished Surface is Not Smooth) .2341
Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction) .2342
Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips) .2343
Machine Speed Does Not Increase While Blade Automatic Control is Activated 2344
Blade Tilt Angle Does Not Align with Design Surface .2345
Blade Tilts While Blade Automatic Control is Activated 2346
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2347
Information Shown in Troubleshooting Table (H-Mode) .2347
System Chart of Hydraulic and Mechanical Systems 2348
Failure Mode and Cause Table 2350
Machine Lacks Power (Drawbar Pull is Not Sufficient) 2358
Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2360
Machine Does Not Move Off at All Gear Speeds 2361
Machine Travels Only in One Direction, Forward or in Reverse 2363
Large Time Lag is in Gear Shifting or Directional Change 2364
Brake Does Not Work .2366
Power Train Oil Overheats .2367
Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor .2369
Torque Converter Lockup Clutch Does Not Engage 2370
Machine Cannot be Steered (Machine Does Not Turn Left or Right) .2371
Steering Speed or Power is Not Sufficient .2372
All Work Equipment Operate Slowly .2373
All Work Equipment Do Not Operate .2374
Blade Lift Speed or Power is Low 2376
Blade Tilt Speed or Power is Low 2377
Blade Angle Speed or Power is Low .2378
Hydraulic Drift of Blade Lift is Large 2379
Hydraulic Drift of Tilted Blade is Large 2380
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2381
Unusual Noise is Heard from Around Fan 2383
Troubleshooting of Engine (S-Mode) 2384
Information Shown in Troubleshooting Table (S-Mode) .2384
Engine Does Not Crank When Starting Switch is Turned to Start Position 2385
Engine Cranks but No Exhaust Smoke Comes Out 2386
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2387
Engine Startability is Unsatisfactory .2389
Engine Does Not Pick Up Smoothly 2391
Engine Stops During Operation .2393
Engine Does Not Rotate Smoothly .2395
Engine Lacks Output (or Lacks Power) 2396
KDPF Becomes Clogged in a Short Time 2398
Engine Oil Consumption is Excessive .2400
Engine Oil Becomes Dirty Quickly 2401
Fuel Consumption is Excessive .2402
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2403
Engine Oil Pressure Drops .2404
Fuel Mixes Into Engine Oil 2406
Water Mixes Into Engine Oil (Milky) .2407
Coolant Temperature Increases Too High (Overheat) .2408
Unusual Noise is Heard 2409
Vibration is Excessive 2410
Air Cannot be Bled from Fuel Circuit 2411
Active Regeneration is Done Frequently 2412
Active Regeneration Continues Long 2414
White Smoke is Exhausted During Active Regeneration .2415
DEF Consumption is Excessive 2416
There is an Unusual Smell (Irritating Odor) .2418
Foreign Materials Enter DEF (DEF Increases) .2419
50 Disassembly and Assembly .2421
Table of Contents .2422
Precautions Before Work .2428
Abbreviation List .2429
Related Information on Disassembly and Assembly .2435
How to Read This Manual .2435
Coating Materials List 2436
Special Tool List .2441
Sketches of Special Tools .2463
Engine and Cooling System .2484
Remove and Install Supply Pump Assembly .2484
Remove Supply Pump Assembly .2484
Install Supply Pump Assembly 2488
Remove and Install Injector Assembly 2493
How to Remove Injector Assembly .2494
How to Install Injector Assembly 2501
Remove and Install Cylinder Head Assembly .2512
How to Remove Cylinder Head Assembly 2513
How to Install Cylinder Head Assembly .2523
Remove and Install EGR Valve Assembly .2539
Remove EGR Valve Assembly .2539
Install EGR Valve Assembly 2540
Remove and Install EGR Cooler Assembly 2541
How to Remove EGR Cooler Assembly .2541
How to Install EGR Cooler Assembly 2542
Remove and Install Starter Assembly .2544
Remove Starting Motor Assembly 2544
Install Starting Motor Assembly .2546
Remove and Install Alternator Belt 2549
Remove Alternator Belt 2549
Install Alternator Belt .2550
Remove and Install Automatic Tensioner 2552
Remove Automatic Tensioner 2552
Install Automatic Tensioner .2552
Remove and Install Radiator Assembly 2553
How to Remove Radiator Assembly .2553
How to Install Radiator Assembly 2556
Remove and Install Hydraulic Oil Cooler Assembly 2560
How to Remove Hydraulic Oil Cooler Assembly .2560
How to Install Hydraulic Oil Cooler Assembly 2562
Remove and Install Aftercooler Assembly .2565
Remove Aftercooler Assembly .2565
Install Aftercooler Assembly 2567
Remove and Install Power Train Oil Cooler Assembly 2570
How to Remove Power Train Oil Cooler Assembly .2570
How to Install Power Train Oil Cooler Assembly 2572
Remove and Install Cooling Fan Drive Assembly .2575
Remove Cooling Fan Drive Assembly .2575
Install Cooling Fan Drive Assembly 2576
Remove and Install Cooling Fan Motor Assembly .2579
Remove Cooling Fan Motor Assembly .2579
Install Cooling Fan Motor Assembly 2581
Remove and Install Engine Assembly 2583
Remove Engine Assembly 2583
Install Engine Assembly .2587
Remove and Install Engine Front Oil Seal 2592
How to Remove Engine Front Oil Seal .2592
How to Install Engine Front Oil Seal 2594
Remove and Install Engine Rear Oil Seal .2598
How to Remove Engine Rear Oil Seal 2598
How to Install Engine Rear Oil Seal .2602
Remove and Install Engine Hood Assembly .2610
How to Remove Engine Hood Assembly 2610
How to Install Engine Hood Assembly .2613
Remove and Install Fuel Tank Assembly .2616
Remove Fuel Tank Assembly .2616
Install Fuel Tank Assembly 2618
Remove and Install DEF Tank Assembly 2620
How to Remove DEF Tank Assembly .2621
How to Install DEF Tank Assembly 2625
Remove and Install DEF Tank Sensor Flange Assembly 2629
How to Remove DEF Tank Sensor Flange Assembly .2630
How to Install DEF Tank Sensor Flange Assembly 2635
Remove and Install DEF Tank Sensor 2641
Remove DEF Tank Sensor 2641
Install DEF Tank Sensor .2642
Remove and Install DEF Tank Strainer 2649
Remove DEF Tank Strainer 2649
Install DEF Tank Strainer .2649
Remove and Install KDPF Assembly 2650
How to Remove KDPF Assembly .2650
How to Install KDPF Assembly 2654
Disassemble and Assemble KDPF Assembly 2658
Disassemble KDPF Assembly .2658
Assemble KDPF Assembly 2662
Remove and Install SCR Assembly .2668
How to Remove SCR Assembly 2668
How to Install SCR Assembly .2670
Remove and Install KDPF and SCR Assembly 2673
How to Remove KDPF and SCR Assembly .2673
Install KDPF and SCR Assembly .2680
Remove and Install KCCV Assembly 2687
Remove KCCV Assembly 2687
Install KCCV Assembly .2689
Remove and Install DEF Mixing Tube 2691
Remove DEF Mixing Tube 2691
Install DEF Mixing Tube .2694
Remove and Install DEF Injector .2699
Remove DEF Injector .2699
Install DEF Injector 2702
Remove and Install DEF Pump .2706
Remove DEF Pump .2706
Install DEF Pump 2709
Remove and Install DEF Hose .2712
Remove DEF Hose .2712
Install DEF Hose 2717
Remove and Install Air Cleaner Assembly .2722
Remove Air Cleaner Assembly .2722
Install Air Cleaner Assembly 2723
Remove and Install Air Conditioner Compressor Assembly 2725
Remove Air Conditioner Compressor Assembly 2725
How to Install Air Conditioner Compressor Assembly 2727
Remove and Install Air Conditioner Condenser Assembly .2730
How to Remove Air Conditioner Condenser Assembly 2730
How to Install Air Conditioner Condenser Assembly .2732
Power Train .2734
Remove and Install Damper Assembly 2734
How to Remove Damper Assembly .2734
How to Install Damper Assembly 2737
Remove and Install Power Train Unit Assembly 2742
Remove Power Train Unit Assembly 2742
How to Install Power Train Unit Assembly 2747
Disconnect and Connect Power Train Unit Assembly 2753
How to Disconnect Power Train Unit Assembly .2753
Connect Power Train Unit Assembly .2758
Disassemble and Assemble PTO Assembly .2764
Disassemble PTO Assembly 2764
Assemble PTO Assembly .2767
Disassemble and Assemble Torque Converter Assembly 2771
Disassemble Torque Converter Assembly .2772
Assemble Torque Converter Assembly 2778
Disassemble and Assemble Transmission Assembly 2787
Disassemble Transmission Assembly .2788
Assemble Transmission Assembly 2806
Disassemble and Assemble HSS Assembly .2826
Disassemble HSS Assembly 2828
Assemble HSS Assembly .2839
Remove and Install HSS Motor Assembly .2856
Remove HSS Motor Assembly .2856
How to Install HSS Motor Assembly .2858
Remove and Install Final Drive Assembly .2861
Remove Final Drive Assembly .2861
Install Final Drive Assembly 2863
Disassemble and Assemble Final Drive Assembly .2866
Disassemble Final Drive Assembly 2868
Assemble Final Drive Assembly .2875
Undercarriage and Frame .2885
Remove and Install Track Frame Assembly .2885
Remove Track Frame Assembly .2885
Install Track Frame Assembly 2887
Remove and Install Idler Assembly .2890
Remove Idler Assembly .2890
Install Idler Assembly 2891
Disassemble and Assemble Idler Assembly .2893
Disassemble Idler Assembly 2893
Assemble Idler Assembly .2895
Remove and Install Recoil Spring Assembly .2899
Remove Recoil Spring Assembly .2899
Install Recoil Spring Assembly 2899
Disassemble and Assemble Recoil Spring Assembly .2901
Disassemble Recoil Spring Assembly 2901
Assemble Recoil Spring Assembly .2904
Remove and Install Track Roller Assembly 2907
Remove Track Roller Assembly 2907
Install Track Roller Assembly .2908
Disassemble and Assemble Track Roller Assembly 2909
Disassemble Track Roller Assembly .2909
Assemble Track Roller Assembly 2911
Remove and Install Carrier Roller Assembly 2914
Remove Carrier Roller Assembly 2914
Install Carrier Roller Assembly .2915
Disassemble and Assemble Carrier Roller Assembly 2916
Disassemble Carrier Roller Assembly .2916
Assemble Carrier Roller Assembly 2917
Remove and Install Pivot Shaft Assembly .2920
Remove Pivot Shaft Assembly .2920
Install Pivot Shaft Assembly 2920
Separate and Connect Track Assembly .2922
Examine Before Separation of Track Assembly .2922
Separate Track Assembly (Standard) 2922
How to Separate Track Assembly (When Track Frame Has Internal Defect) .2923
Install Track Assembly 2924
Separate and Connect PLUS Type Track Assembly .2927
Separate PLUS Type Track Assembly Generally .2927
Install PLUS Type Track Assembly 2927
Disassemble and Assemble Track Assembly Generally .2928
How to Disassemble Full Track Shoes Assembly 2928
How to Assemble Full Track Shoes Assembly .2931
Disassemble and Assemble PLUS Type Track Assembly Generally .2943
Disassemble PLUS Type Track Assembly Generally 2944
How to Assemble PLUS Type Track Shoes Assembly Generally 2945
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2960
Disassemble One Track Link Assembly in Field (Track Assembly) .2961
Assemble One Track Link Assembly in Field (Track Assembly) 2962
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2969
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) .2970
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2972
Remove and Install Equalizer Bar Assembly .2976
Remove Equalizer Bar Assembly .2976
Install Equalizer Bar Assembly 2977
Disassemble and Assemble Equalizer Bar Bushing 2979
Disassemble Equalizer Bar Bushing .2979
Assemble Equalizer Bar Bushing 2979
Hydraulic System 2981
Remove and Install Hydraulic Tank Assembly 2981
Remove Hydraulic Tank Assembly 2981
How to Install Hydraulic Tank Assembly 2984
Remove and Install HSS Pump and Cooling Fan Pump Assembly .2989
How to Remove HSS Pump and Cooling Fan Pump Assembly 2989
How to Install HSS Pump and Cooling Fan Pump Assembly .2990
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2993
Remove Power Train Pump and Steering Lubrication Pump Assembly 2993
Install Power Train Pump and Steering Lubrication Pump Assembly .2995
Remove and Install Scavenging Pump Assembly .2998
Remove Scavenging Pump Assembly .2998
Install Scavenging Pump Assembly 2998
Remove and Install 3 Spool Control Valve Assembly .3000
How to Remove 3 Spool Control Valve Assembly 3000
How to Install 3 Spool Control Valve Assembly .3003
Disassemble and Assemble Blade PPC Valve 3007
How to Disassemble Blade PPC Valve 3007
How to Assemble Blade PPC Valve .3007
Work Equipment 3009
Remove and Install Tilt Dozer and Power Tilt Pitch Dozer Series .3009
How to Remove Tilt Dozer and Power Tilt Pitch Dozer Series 3009
How to Install Tilt Dozer and Power Tilt Pitch Dozer Series .3011
Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series) .3015
How to Remove Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series) 3015
How to Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series) 3017
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3021
Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly .3022
Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 3027
CAB Related Parts .3038
Remove and Install Operator Cab Assembly 3038
How to Remove Operator Cab Assembly .3038
Install Operator CAB Assembly .3049
Remove and Install Operator Cab Glass (Adhered Glass) .3061
Remove Operator CAB Glass (Adhered Glass) .3061
Install Operator CAB Glass (Adhered Glass) 3062
Remove and Install Air Conditioner Unit Assembly 3067
Remove Air Conditioner Unit Assembly 3067
Install Air Conditioner Unit Assembly .3073
Remove and Install Operator Seat 3080
Remove Operator’s Seat 3080
Install Operator’s Seat .3082
How to Remove and Install Seat Belt .3084
How to Remove Seat Belt .3084
How to Install Seatbelt .3085
Electrical System .3086
Remove and Install Engine Controller Assembly .3086
Remove Engine Controller Assembly .3086
Install Engine Controller Assembly 3087
Remove and Install Power Train Controller Assembly 3090
Remove Power Train Controller Assembly 3090
Install Power Train Controller Assembly .3091
Remove and Install Radio Control Controller .3093
How to Remove Radio Control Controller 3093
How to Install Radio Control Controller .3093
Remove and Install Machine Monitor Assembly .3095
Remove Machine Monitor Assembly .3095
Install Machine Monitor Assembly 3096
Remove and Install Mass Air Flow and Temperature Sensor .3098
How to Remove Mass Air Flow and Temperature Sensor 3098
How to Install Mass Air Flow and Temperature Sensor .3099
Remove and Install KCCV Crankcase Pressure Sensor .3100
How to Remove KCCV Crankcase Pressure Sensor 3100
How to Install KCCV Crankcase Pressure Sensor .3101
Remove and Install SCR Temperature Sensor .3102
Remove SCR Temperature Sensor .3102
Install SCR Temperature Sensor 3104
Remove and Install KOMTRAX Terminal Assembly 3106
Remove KOMTRAX Terminal Assembly 3106
Install KOMTRAX Terminal Assembly .3108
Remove and Install Gateway Function Controller Assembly .3111
How to Remove Gateway Function Controller Assembly 3111
How to Install Gateway Function Controller Assembly .3114
Remove and Install Communication Terminal .3118
How to Remove Communication Terminal 3118
How to Install Communication Terminal .3121
Remove and Install ICT Sensor Controller Assembly .3124
Remove ICT Sensor Controller Assembly .3124
Install ICT Sensor Controller Assembly 3124
Remove and Install Control Box 3126
How to Remove Control Box (For Old Control Box) .3126
How to Remove Control Box (For New Control Box) .3127
How to Install Control Box (For Old Control Box) 3127
How to Install Control Box (For New Control Box) 3128
Remove and Install GNSS Receiver 3130
Remove GNSS Receiver 3130
Install GNSS Receiver .3131
Remove and Install GNSS Antenna .3132
Remove GNSS Antenna .3132
Install GNSS Antenna 3133
Remove and Install IMU Sensor .3138
Remove IMU Sensor .3138
Install IMU Sensor 3140
Remove and Install Radio Control Receiver .3143
How to Remove Radio Control Receiver 3143
How to Install Radio Control Receiver .3143
Remove and Install Revolving Lamp .3145
Remove Revolving Lamp .3145
Install Revolving Lamp 3146
60 Maintenance Standard .3147
Table of Contents .3148
Abbreviation List .3150
Engine and Cooling System .3156
Maintenance Standard for Engine Mount .3156
Maintenance Standard for Damper .3157
Maintenance Standard for Cooling System .3159
Maintenance Standard for Cooling Fan Pump .3161
Maintenance Standard for Servo Valve 3162
Maintenance Standard for Cooling Fan Motor 3163
Power Train .3165
Maintenance Standard for Universal Joint 3165
Maintenance Standard for Power Train Mount 3166
Maintenance Standard for Torque Converter and PTO .3168
Maintenance Standard for Lockup Clutch ECMV .3171
Maintenance Standard for Transmission .3172
Maintenance Standard for Transmission Control Valve .3177
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV .3178
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 3179
Maintenance Standard for Transmission Lubrication Relief Valve 3180
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake .3181
Maintenance Standard for Brake Valve 3186
Maintenance Standard for Brake ECMV .3187
Maintenance Standard for Sudden Stop Prevention Valve .3188
Maintenance Standard for Parking Brake Valve 3189
Maintenance Standard for Final Drive 3191
Maintenance Standard for Sprocket for PLUS Type Track Shoes .3194
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3195
Undercarriage and Frame .3197
Maintenance Standard for Main Frame .3197
Maintenance Standard for Suspension .3198
Maintenance Standard for Track Frame and Idler Cushion 3200
Maintenance Standard for Idler 3202
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 3204
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 3205
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes .3206
Maintenance Standard for PLUS Type Track Shoes 3207
Maintenance Standard for Single Shoes .3209
Hydraulic System 3210
Maintenance Standard for Hydraulic Tank .3210
Maintenance Standard for Scavenging Pump 3211
Maintenance Standard for Steering Lubrication Pump and Power Train Pump .3212
Maintenance Standard for Work Equipment and HSS Pump 3213
Maintenance Standard for PC-EPC Valve .3214
Maintenance Standard for HSS Motor 3215
Maintenance Standard for Control Valve 3217
Maintenance Standard for Blade PPC Valve 3225
Maintenance Standard for Quick Drop Valve .3227
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer Series) .3229
Work Equipment 3230
Maintenance Standard for Front Work Equipment .3230
Maintenance Standard for Cutting Edge and End Bit .3233
Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series) 3234
Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series) .3235
Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series) .3236
CAB Related Parts .3238
Maintenance Standard for CAB Mount 3238
80 Appendix .3239
Table of Contents .3240
Precautions Before Work .3242
Abbreviation List .3243
Air Conditioner System 3249
Precautions for Refrigerant .3249
Air Conditioner Component .3250
Specifications of Air Conditioner .3252
Structure and Function of Refrigeration Cycle .3253
Outline of Refrigeration Cycle 3254
Component Parts of Air Conditioner System .3256
Air Conditioner Unit 3256
Configuration Diagram of Air Conditioner Unit .3256
Function of Air Conditioner Unit 3258
Component Parts of Air Conditioner Unit .3260
Function of Evaporator as Air Conditioner Unit Component 3261
Function of Heater Core as Air Conditioner Unit Component .3261
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .3261
Function of Servo Motor as Air Conditioner Unit Component .3261
Structure of Expansion Valve as Air Conditioner Unit Component 3262
Function of Expansion Valve as Air Conditioner Unit Component .3262
Operate Expansion Valve as Air Conditioner Unit Component .3262
Function of Dual Pressure Switch 3263
Air Conditioner Controller 3264
Structure of Air Conditioner Controller .3264
Compressor 3265
Structure of Compressor .3265
Specifications of Compressor 3265
Function of Compressor 3265
Condenser .3266
Structure of Standard Core Condenser 3266
Specifications of Standard Core Condenser .3266
Function of Standard Core Condenser .3266
Structure of Wide Core Condenser 3267
Specifications of Wide Core Condenser .3267
Function of Wide Core Condenser .3267
Receiver Drier 3268
Structure of Receiver Dryer .3268
Specifications of Receiver Dryer 3268
Function of Receiver Dryer 3268
Air Conditioner Related Sensors .3269
Structure of Sunlight Sensor 3269
Function of Sunlight Sensor .3269
Structure of Outside Temperature Sensor .3269
Function of Outside Air Temperature Sensor 3269
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .3271
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3273
System Diagram of Air Conditioner .3275
Input and Output Signals of Air Conditioner Controller 3276
Function of Air Conditioner Controller 3277
Locations of Air Conditioner Parts and Layout of Connectors .3278
Examine Air Leakage (Duct) 3287
How to Examine Air Leakage (Duct) .3287
Explanation for Test of Air Conditioner with Self-Diagnosis Function 3290
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .3291
Examine Vent (Mode) Changeover 3292
How to Examine Vent (Mode) Changeover .3292
Examine Fresh/Recirc Air Changeover .3293
How to Examine Fresh/Recirc Air Changeover 3293
Examine Sunlight Sensor .3294
How to Examine Sunlight Sensor 3294
Examine Refrigerant (Dual) Pressure Switch 3295
How to Examine Refrigerant (Dual) Pressure Switch .3295
Examine Relay .3296
How to Examine Relay 3296
Air Conditioner Troubleshooting Chart 1 .3297
Air Conditioner Troubleshooting Chart 2 .3298
Information Shown in Troubleshooting Table 3301
Failure Code [879AKA] .3302
Failure Code [879AKB] .3303
Failure Code [879BKA] .3304
Failure Code [879BKB] .3306
Failure Code [879CKA] .3308
Failure Code [879CKB] .3309
Failure Code [879DKZ] .3310
Failure Code [879EMC] .3312
Failure Code [879FMC] .3313
Failure Code [879GKX] .3314
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3316
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .3318
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3322
Troubleshooting for Fresh/Recirc Air Changeover .3324
Troubleshooting by Gauge Pressure .3326
Connect Service Tool 3329
How to Connect Service Tool .3329
Precautions for Disconnection and Connection of Air Conditioner Piping 3331
Handle Compressor Oil .3333
90 Circuit Diagrams .3335
Table of Contents .3336
Abbreviation List .3337
Hydraulic Circuit Diagram .3343
Symbols Used in Hydraulic Circuit Diagram .3343
Hydraulic Circuit Diagram .3347
Power Train Hydraulic Circuit Diagram .3349
Electrical Circuit Diagram 3351
Symbols Used in Electric Circuit Diagram 3351
Electrical Circuit Diagram (1/17) .3355
Electrical Circuit Diagram (2/17) .3357
Electrical Circuit Diagram (3/17) .3359
Electrical Circuit Diagram (4/17) .3361
Electrical Circuit Diagram (5/17) .3363
Electrical Circuit Diagram (6/17) .3365
Electrical Circuit Diagram (7/17) .3367
Electrical Circuit Diagram (8/17) .3369
Electrical Circuit Diagram (9/17) .3371
Electrical Circuit Diagram (10/17) 3373
Electrical Circuit Diagram (11/17) 3375
Electrical Circuit Diagram (12/17) 3377
Electrical Circuit Diagram (13/17) 3379
Electrical Circuit Diagram (14/17) 3381
Electrical Circuit Diagram (15/17) 3383
Electrical Circuit Diagram (16/17) 3385
Electrical Circuit Diagram (17/17) 3387
Index 3389

DESCRIPTION:

Komatsu Bulldozer D65PXi-18 Shop Manual SEN06620-12 –  PDF DOWNLOAD

• SERIAL NUMBERS  90023 and up

G.B 27/12/24