Komatsu BULLDOZER D85EX -18 D85PX-18 Shop Manual SEN06901-05 PDF
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Komatsu BULLDOZER D85EX -18 D85PX-18 Shop Manual SEN06901-05 – PFD DOWNLOAD
SERIAL NUMBERS 25001 and up
Description
Komatsu BULLDOZER D85EX -18 D85PX-18 Shop Manual SEN06901-05 – PFD DOWNLOAD
FILE DETAILS:
Komatsu BULLDOZER D85EX -18 D85PX-18 Shop Manual SEN06901-05 – PFD DOWNLOAD
Language : English
Pages :2948
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu BULLDOZER D85EX -18 D85PX-18 Shop Manual SEN06901-05 – PFD DOWNLOAD
SERIAL NUMBERS 25001 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 D85EX -18 D85PX-18 Shop Manual SEN06901-05 – PFD DOWNLOAD
SERIAL NUMBERS 25001 and up
Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 22
Foreword, Safety, Basic Information 25
How to Read the Shop Manual 25
Safety Notice for Operation 27
Precautions to Prevent Fire 35
Procedures If Fire Occurs 37
Precautions When You Discard Waste Materials 38
Procedures for Exhaust Gas Regulations 39
Precautions for DEF 40
General Character and Precautions for Handling 40
Precautions for Adding 40
Precautions for Storage 40
Precautions for Fire Hazard and Leakage 40
Other Precautions 40
Store DEF 41
Precautions When You Handle Hydraulic Equipment 42
Precautions When You Disconnect and Connect Pipings 45
Precautions When You Handle Electrical Equipment 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate 70
How to Read the Codes for Electric Cable 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table 78
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: D85EX-18 93
Specification Drawing: D85PX-18 95
Specifications 97
Specifications: D85EX-18 97
Specifications: D85PX-18 104
Weight Table 109
Weight Table: D85EX-18 109
Weight Table: D85PX-18 112
Fuel, Coolant, Lubricant 115
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 115
10 Structure and Function 117
Table of Contents 118
Urea SCR System 121
Layout Drawing of Urea SCR System 121
Urea SCR System Diagram 124
Function of Urea SCR System 125
Function of DEF System 125
Inducement Strategy 127
Component Parts of Urea SCR System 142
DEF Mixing Tube 142
SCR Assembly 142
DEF Tank 145
DEF Pump 147
DEF Injector 148
DEF Hose 149
DEF Tank Heating Valve 150
Boot-up System 151
Layout Drawing of Boot-up System 151
System Operating Lamp System 152
System Diagram of System Operating Lamp System 152
Function of Operation Lamp System 152
Battery Disconnect Switch 153
Layout Drawing of Battery Disconnect Switch 153
Function of Battery Disconnect Switch 153
Engine System 155
Layout Drawing of Engine System 155
Engine Control System 157
Layout Drawing of Engine Control System 157
System Diagram of Engine Control 158
Function of Engine Control System 160
Automatic Idle Stop System 162
System Diagram of Automatic Idle Stop System 162
Function of Automatic Idle Stop System 162
Component Parts of Engine System 165
Damper 165
VGT 166
EGR System 170
EGR Valve 172
EGR Cooler 174
KCCV System 175
KCCV Ventilator 177
KDPF 179
Cooling System 184
Layout Drawing of Cooling System 184
Specifications of Cooling System 185
Cooling Fan Control System 186
System Diagram of Cooling Fan Control System 186
Function of Cooling Fan Control System 187
Component Parts of Cooling System 189
Cooling Fan Pump 189
Cooling Fan Motor 198
Hydraulic Oil Cooler Bypass Valve 205
Control System 206
Layout Drawing of Control System 206
Machine Monitor System 207
System Diagram of Machine Monitor System 207
Function of Machine Monitor System 207
KOMTRAX System 209
System Diagram of KOMTRAX System 209
Function of KOMTRAX System 209
Component Parts of Control System 210
Machine Monitor 210
Gateway Function Controller 226
Communication Terminal 229
Power Train Controller 231
Engine Controller 235
Fuel Feed Pump 241
Fuel Feed Pump Switch 242
Hydraulic System 243
Layout Drawing of Hydraulic System 243
CLSS 244
Structure of CLSS 244
Function of CLSS 245
Component Parts of Hydraulic System 247
Hydraulic Tank 247
Work Equipment and HSS Pump 248
LS Valve 254
TVC Valve 258
Variable Throttle Valve 262
Control Valve 264
Power Train System 298
Layout Drawing of Power Train System 298
Operation of Power Train System 300
Transmission, Steering, and Brake Control 301
Layout Drawing of Transmission, Steering, and Brake Control System 301
Function of Transmission, Steering, and Brake Control 302
Palm Command Control System 304
Palm Command Control System Diagram 304
HSS System 308
HSS System Diagram 308
Function of HSS System 309
Centralized Pressure Pickup Port 311
Layout Drawing of Centralized Pressure Pickup Port 311
Function of Centralized Pressure Pickup Port 312
Component Parts of Power Train System 313
Universal Joint 313
Power Train Mount 314
Torque Converter and PTO 315
Transmission 318
Transmission ECMV 328
Main Relief Valve and Torque Converter Relief Valve 334
Transmission Lubrication Relief Valve 336
Bevel Gear Shaft, HSS, and Brake 336
Brake Valve 356
Final Drive 359
Scavenging Pump 363
Steering Lubrication Pump and Power Train Pump 364
HSS Motor 365
Electric Steering Electric Lever 370
Work Equipment System 374
Work Equipment Control 374
Layout Drawing of Work Equipment Control 374
Function of Work Equipment Control 375
Layout Drawing of Front Work Equipment 377
Layout Drawing of Fixed Multi-Shank Ripper 378
Layout Drawing of Variable Multi-Shank Ripper 379
Component Parts of Work Equipment System 380
Self-Pressure Reducing Valve 380
Work Equipment Lock Solenoid Valve 386
Blade PPC Valve 387
Ripper PPC Valve 393
Blade Pitch Selector Solenoid Valve 397
Pilot Circuit Accumulator 399
Quick Drop Valve 400
Piston Valve 401
Undercarriage and Frame 403
Main Frame 403
Structure of Main Frame 403
Suspension 404
Structure of Suspension 404
Function of Suspension 407
Track Frame and Idler Cushion 408
Structure of Track Frame and Idler Cushion 408
Function of Track Frame and Idler Cushion 409
Work Equipment 410
Structure of Front Work Equipment 410
Structure of Cylinder Stay 412
Structure of Fixed Multi-Shank Ripper 413
Structure of Variable Multi-Shank Ripper 414
CAB Related Parts 415
ROPS CAB 415
Structure of ROPS CAB 415
Function of ROPS CAB 416
CAB Mount 417
Structure of CAB Mount 417
Function of CAB Mount 417
20 Standard Value Table 419
Table of Contents 420
Standard Value Table for Engine 421
Standard Value Table for Engine: D85EX-18 421
Standard Value Table for Engine: D85PX-18 424
Standard Value Table for Machine 427
Standard Value Table for Machine: D85EX-18 427
Standard Value Table for Machine: D85PX-18 444
Machine Posture and Procedures to Measure Performance 459
30 Testing and Adjusting 463
Table of Contents 464
Precautions Before Work 467
Related Information on Testing and Adjusting 468
Tools for Testing and Adjusting 468
Sketch of Tools for Testing and Adjusting 475
Engine and Cooling System 476
Examine Engine Speed 476
How to Examine Engine Speed 476
Examine Boost Pressure 480
How to Examine Boost Pressure 480
Examine Exhaust Gas Temperature 482
How to Examine Exhaust Gas Temperature 482
Examine Exhaust Gas Color 484
How to Examine Exhaust Gas Color with the Handy Smoke Checker 484
How to Examine Exhaust Gas Color with Smoke Meter 485
Examine and Adjust Valve Clearance 487
How to Examine Valve Clearance 487
How to Adjust Valve Clearance 488
Examine Compression Pressure 489
How to Examine Compression Pressure 489
Examine Blowby Pressure 493
How to Examine Blowby Pressure 493
Examine Engine Oil Pressure 496
How to Examine Engine Oil Pressure on Machine Monitor 496
How to Examine Engine Oil Pressure by Testing Tool 496
Examine EGR Valve and VGT Oil Pressure 498
How to Examine EGR Valve and VGT Oil Pressure 498
Examine Fuel Pressure 500
How to Examine Fuel Pressure 500
Examine Fuel Return Rate and Leakage 502
How to Examine Fuel Return Rate and Leakage 503
Bleed Air from Fuel System 506
How to Bleed Air from Fuel System 507
Examine Fuel Circuit for Leakage 508
How to Examine Fuel System for Leakage 508
Handle Cylinder Cut-out Mode Operation 510
Handle No-Injection Cranking Operation 511
Examine and Adjust Air Conditioner Compressor Belt Tension 512
How to Examine Air Conditioner Compressor Drive Belt Tension 512
How to Adjust Air Conditioner Compressor Belt Tension 512
Clean Fuel Doser 514
How to Clean Fuel Doser 514
Write Injector Compensation Value to Engine Controller 517
How to Write Injector Compensation Value 517
Write Correction for Ash in Soot Accumulation to Engine Controller 523
How to Write Correction for Ash in Soot Accumulation to Engine Controller 523
Examine SCR Related Functions 524
Examine DEF Pump Raised Pressure 527
Examine Injection Volume from DEF Injector 529
Examine DEF Line Heater Relay 1 534
Examine DEF Line Heater Relay 2 536
Examine DEF Pump Heater Relay 539
Examine DEF Tank Heater Valve 542
Examine SCR Denitration Efficiency 544
Clean DEF Tank 548
How to Clean DEF Tank 548
Clean DEF Pump 552
How to Clean DEF Pump 552
Clean DEF Tank Mounting Part 559
How to Clean DEF Tank Mounting Part 559
Adjust Decelerator Pedal 560
How to Adjust Decelerator Pedal 560
Power Train 562
Examine Power Train Oil Pressure 562
How to Examine Power Train Oil Pressure 563
Adjust Transmission Output Shaft Speed Sensor 574
How to Adjust Transmission Output Shaft Speed Sensor 574
Examine Brake Performance Simply 576
How to Examine Brake Performance Simply 576
Adjust Brake Pedal 577
How to Adjust Brake Pedal 577
Adjust Parking Brake Lever 579
How to Adjust Parking Brake Lever 579
Move Machine by Parking Brake Release When Machine Does Not Travel 581
How to Move Machine with Hydraulic Type Parking Brake Release System 581
How to Move Machine with Electric Type Parking Brake Release System 582
Undercarriage and Frame 584
Adjust Idler Clearance 584
How to Adjust Idler Clearance 584
How to Adjust Idler Clearance Horizontally 584
How to Adjust Idler Clearance Vertically 584
Examine and Adjust Track Tension 586
How to Examine 586
How to Adjust Track Tension 586
Hydraulic System 587
Release Remained Pressure in Hydraulic Circuit 587
How to Release Remained Pressure in Hydraulic System 587
Examine and Adjust Work Equipment and HSS Oil Pressure 588
How to Examine Work Equipment and HSS Oil Pressure 588
How to Adjust Oil Pressure of Work Equipment and HSS 592
Examine Oil Pressure of Control Circuit 593
How to Examine Oil Pressure in Control Circuit 593
Examine PPC Valve Outlet Pressure 595
How to Examine Outlet Pressure in PPC Valve 595
Bleed Air from HSS Pump 598
How to Bleed Air from HSS Pump 598
Examine and Adjust Play of Work Equipment PPC Valve 599
How to Examine Play of Work Equipment PPC Valve 599
How to Adjust Play of Work Equipment PPC Valve 600
Examine Cooling Fan Speed 601
How to Examine Cooling Fan Speed 601
Examine Cooling Fan Circuit Oil Pressure 602
How to Examine Cooling Fan Circuit Oil Pressure 602
Bleed Air in Cooling Fan Pump 604
How to Bleed Air in Cooling Fan Pump 604
Examine Parts Which Cause Hydraulic Drift of Work Equipment 605
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 605
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 605
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 606
Examine Oil Leakage from Work Equipment Cylinder 607
How to Examine Internal Oil Leakage of Work Equipment Cylinder 607
Bleed Air from Work Equipment Cylinders 609
How to Bleed Air from Work Equipment Cylinder 609
Work Equipment 610
Adjust Work Equipment Lock Lever 610
How to Adjust Work Equipment Lock Lever 610
CAB Related Parts 612
Examine and Adjust Operator Cab 612
How to Examine Operator Cab 612
How to Adjust Operator Cab 614
Electrical System 617
Set and Operate Machine Monitor 617
Operator Mode 620
Function to Show Technician Identification Status Screen 620
Function to Show Operator Identification Input Screen 621
Examine Function by LCD (Liquid Crystal Display) 621
Examine Function of Service Meter 622
How to Set Usage Limitation and Change Maintenance Password 622
Service Mode 624
How to Operate Service Mode 624
How to See Pre-defined Monitoring Information 626
How to Examine Self-Define Monitor Information 631
Abnormality Record Menu 641
How to See Maintenance Record 645
Maintenance Mode Setting 646
How to Set Phone Number Entry 650
Default Menu 651
Diagnostic Tests Menu 659
Adjustment Menu 668
No-Injection Cranking Operation 695
KOMTRAX Settings Menu 696
How to Show Service Message 698
How to Start Up KOMTRAX System 700
How to Stop Use of KOMTRAX System 705
Adjust When Power Train Controller is Replaced 707
How to Adjust When Power Train Controller is Replaced 707
Adjust Rearview Camera Angle 710
How to Adjust Rearview Camera Angle 710
Set Region of Bluetooth(R) Compatible Radio 711
How to Set Region of Bluetooth(R) Compatible Radio 711
Handle Voltage Circuit of Engine Controller 713
Handle Battery Disconnect Switch 714
Examine Diodes 715
How to Examine Diodes by Digital Tester 715
How to Examine Diodes by Analog Tester 715
Pm Clinic 716
Pm Clinic Service 716
Pm Clinic Check Sheet: D85EX-18 717
Pm Clinic Check Sheet: D85PX-18 731
Pm Clinic Check Sheet for Undercarriage: D85EX-18 742
Pm Clinic Check Sheet for Undercarriage: D85PX-18 746
40 Troubleshooting 751
Table of Contents 752
Precautions Before Work 762
Related Information to Troubleshooting 763
General Troubleshooting Points 763
Troubleshooting Points for Urea SCR System 764
Sequence of Events in Troubleshooting 778
Checks Before Troubleshooting 780
Inspection Procedure Before Troubleshooting 782
Walk-Around Check 782
Test in Accordance with Testing Procedure 784
How to Examine Electric Equipment 784
Preparation for Troubleshooting of Electrical System 791
Procedure for Troubleshooting 799
Symptom and Troubleshooting Numbers 802
Information Shown in Troubleshooting Table 805
Connector List and Layout (Applicable Machine:25001 to 25152) 807
Connector List and Layout (Applicable Machine:25153 and up) 822
Connector Contact Connection Table 837
T-Branch Box and T-Branch Adapter Table 877
Fuse Location Table 883
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 886
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 890
Failure Code Table 892
Troubleshooting by Failure Code (Display of Code) 911
Failure Code [1500L0] 911
Failure Code [15SAL1] 912
Failure Code [15SALH] 914
Failure Code [15SBL1] 916
Failure Code [15SBLH] 918
Failure Code [15SEL1] 920
Failure Code [15SELH] 922
Failure Code [15SFL1] 924
Failure Code [15SFLH] 926
Failure Code [15SGL1] 928
Failure Code [15SGLH] 930
Failure Code [1800MW] 932
Failure Code [879AKA] 933
Failure Code [879AKB] 934
Failure Code [879BKA] 935
Failure Code [879BKB] 937
Failure Code [879CKA] 939
Failure Code [879CKB] 940
Failure Code [879DKZ] 941
Failure Code [879EMC] 943
Failure Code [879FMC] 944
Failure Code [879GKX] 945
Failure Code [989L00] 947
Failure Code [989M00] 948
Failure Code [989N00] 949
Failure Code [A1U0N3] 950
Failure Code [A1U0N4] 952
Failure Code [A900FR] 954
Failure Code [A900N6] 955
Failure Code [A900NY] 956
Failure Code [AA10NX] 957
Failure Code [AB00KE] 959
Failure Code [AQ10N3] 961
Failure Code [AS00N3] 963
Failure Code [AS00R2] 965
Failure Code [AS00R3] 966
Failure Code [AS00R4] 967
Failure Code [AS00R5] 968
Failure Code [AS00R6] 969
Failure Code [AS00ZK] 970
Failure Code [AS10KM] 971
Failure Code [AS10NR] 972
Failure Code [AS10NT] 973
Failure Code [B@BAZG] 974
Failure Code [B@BCNS] 975
Failure Code [B@BCZK] 976
Failure Code [B@CENS] 978
Failure Code [B@HANS] 979
Failure Code [CA115] 980
Failure Code [CA122] 981
Failure Code [CA123] 983
Failure Code [CA131] 985
Failure Code [CA132] 987
Failure Code [CA135] 989
Failure Code [CA141] 991
Failure Code [CA144] 993
Failure Code [CA145] 995
Failure Code [CA153] 997
Failure Code [CA154]1000
Failure Code [CA187]1003
Failure Code [CA221]1005
Failure Code [CA222]1007
Failure Code [CA227]1009
Failure Code [CA234]1010
Failure Code [CA238]1011
Failure Code [CA239]1013
Failure Code [CA249]1015
Failure Code [CA256]1017
Failure Code [CA271]1019
Failure Code [CA272]1021
Failure Code [CA273]1022
Failure Code [CA274]1024
Failure Code [CA322]1025
Failure Code [CA323]1027
Failure Code [CA324]1029
Failure Code [CA325]1031
Failure Code [CA331]1033
Failure Code [CA332]1035
Failure Code [CA343]1037
Failure Code [CA351]1038
Failure Code [CA352]1039
Failure Code [CA356]1042
Failure Code [CA357]1044
Failure Code [CA386]1046
Failure Code [CA441]1047
Failure Code [CA442]1050
Failure Code [CA449]1051
Failure Code [CA451]1052
Failure Code [CA452]1054
Failure Code [CA515]1056
Failure Code [CA516]1058
Failure Code [CA553]1060
Failure Code [CA555]1061
Failure Code [CA556]1062
Failure Code [CA559]1063
Failure Code [CA595]1068
Failure Code [CA687]1069
Failure Code [CA689]1071
Failure Code [CA691]1073
Failure Code [CA692]1075
Failure Code [CA697]1077
Failure Code [CA698]1078
Failure Code [CA731]1079
Failure Code [CA778]1080
Failure Code [CA1117]1083
Failure Code [CA1664]1084
Failure Code [CA1669]1087
Failure Code [CA1673]1088
Failure Code [CA1677]1089
Failure Code [CA1678]1090
Failure Code [CA1682]1091
Failure Code [CA1683]1093
Failure Code [CA1684]1095
Failure Code [CA1686]1097
Failure Code [CA1691]1098
Failure Code [CA1694]1101
Failure Code [CA1695]1103
Failure Code [CA1696]1104
Failure Code [CA1712]1106
Failure Code [CA1713]1109
Failure Code [CA1714]1111
Failure Code [CA1715]1112
Failure Code [CA1776]1113
Failure Code [CA1777]1116
Failure Code [CA1843]1119
Failure Code [CA1844]1121
Failure Code [CA1879]1124
Failure Code [CA1881]1127
Failure Code [CA1883]1130
Failure Code [CA1885]1134
Failure Code [CA1887]1136
Failure Code [CA1921]1138
Failure Code [CA1922]1141
Failure Code [CA1923]1146
Failure Code [CA1924]1148
Failure Code [CA1925]1150
Failure Code [CA1927]1152
Failure Code [CA1928]1154
Failure Code [CA1942]1156
Failure Code [CA1963]1157
Failure Code [CA1977]1160
Failure Code [CA1993]1163
Failure Code [CA2185]1166
Failure Code [CA2186]1167
Failure Code [CA2249]1169
Failure Code [CA2265]1170
Failure Code [CA2266]1172
Failure Code [CA2271]1175
Failure Code [CA2272]1177
Failure Code [CA2349]1179
Failure Code [CA2353]1181
Failure Code [CA2357]1183
Failure Code [CA2381]1184
Failure Code [CA2382]1186
Failure Code [CA2383]1188
Failure Code [CA2386]1190
Failure Code [CA2387]1192
Failure Code [CA2555]1193
Failure Code [CA2556]1196
Failure Code [CA2637]1198
Failure Code [CA2639]1200
Failure Code [CA2732]1203
Failure Code [CA2733]1205
Failure Code [CA2741]1207
Failure Code [CA2765]1208
Failure Code [CA2771]1209
Failure Code [CA2777]1215
Failure Code [CA2878]1218
Failure Code [CA2881]1221
Failure Code [CA2976]1224
Failure Code [CA3133]1226
Failure Code [CA3134]1228
Failure Code [CA3135]1230
Failure Code [CA3142]1234
Failure Code [CA3143]1235
Failure Code [CA3144]1236
Failure Code [CA3146]1238
Failure Code [CA3147]1239
Failure Code [CA3148]1240
Failure Code [CA3151]1242
Failure Code [CA3165]1248
Failure Code [CA3167]1250
Failure Code [CA3229]1253
Failure Code [CA3231]1255
Failure Code [CA3232]1257
Failure Code [CA3235]1261
Failure Code [CA3239]1263
Failure Code [CA3241]1266
Failure Code [CA3242]1269
Failure Code [CA3251]1272
Failure Code [CA3253]1275
Failure Code [CA3254]1279
Failure Code [CA3255]1282
Failure Code [CA3256]1286
Failure Code [CA3311]1288
Failure Code [CA3312]1290
Failure Code [CA3313]1293
Failure Code [CA3314]1294
Failure Code [CA3315]1295
Failure Code [CA3316]1298
Failure Code [CA3317]1299
Failure Code [CA3318]1300
Failure Code [CA3319]1303
Failure Code [CA3321]1304
Failure Code [CA3322]1306
Failure Code [CA3419]1309
Failure Code [CA3421]1311
Failure Code [CA3497]1313
Failure Code [CA3498]1314
Failure Code [CA3543]1315
Failure Code [CA3545]1322
Failure Code [CA3547]1324
Failure Code [CA3558]1325
Failure Code [CA3559]1327
Failure Code [CA3562]1329
Failure Code [CA3563]1331
Failure Code [CA3567]1334
Failure Code [CA3568]1337
Failure Code [CA3571]1341
Failure Code [CA3572]1343
Failure Code [CA3574]1345
Failure Code [CA3575]1347
Failure Code [CA3577]1349
Failure Code [CA3578]1351
Failure Code [CA3582]1353
Failure Code [CA3583]1360
Failure Code [CA3596]1362
Failure Code [CA3649]1364
Failure Code [CA3681]1366
Failure Code [CA3682]1371
Failure Code [CA3713]1377
Failure Code [CA3717]1380
Failure Code [CA3718]1381
Failure Code [CA3725]1382
Failure Code [CA3748]1385
Failure Code [CA3751]1388
Failure Code [CA3755]1390
Failure Code [CA3866]1392
Failure Code [CA3867]1396
Failure Code [CA3868]1399
Failure Code [CA3899]1403
Failure Code [CA3911]1405
Failure Code [CA3912]1409
Failure Code [CA3932]1411
Failure Code [CA3933]1413
Failure Code [CA3934]1415
Failure Code [CA3935]1418
Failure Code [CA3936]1420
Failure Code [CA4151]1422
Failure Code [CA4152]1426
Failure Code [CA4155]1430
Failure Code [CA4156]1432
Failure Code [CA4157]1435
Failure Code [CA4158]1437
Failure Code [CA4159]1438
Failure Code [CA4161]1439
Failure Code [CA4162]1442
Failure Code [CA4163]1445
Failure Code [CA4164]1447
Failure Code [CA4165]1449
Failure Code [CA4166]1451
Failure Code [CA4168]1453
Failure Code [CA4169]1456
Failure Code [CA4171]1458
Failure Code [CA4249]1461
Failure Code [CA4251]1463
Failure Code [CA4259]1465
Failure Code [CA4261]1468
Failure Code [CA4277]1470
Failure Code [CA4281]1474
Failure Code [CA4459]1478
Failure Code [CA4461]1481
Failure Code [CA4658]1484
Failure Code [CA4731]1488
Failure Code [CA4732]1489
Failure Code [CA4739]1490
Failure Code [CA4768]1491
Failure Code [CA4769]1493
Failure Code [CA4842]1496
Failure Code [CA4952]1500
Failure Code [CA5115]1502
Failure Code [CA5383]1505
Failure Code [D130KA]1507
Failure Code [D130KB]1510
Failure Code [D19DKA]1512
Failure Code [D19DKB]1514
Failure Code [D19JKZ]1516
Failure Code [D19UKA]1519
Failure Code [D19UKB]1521
Failure Code [D19UMC]1523
Failure Code [D811MC]1525
Failure Code [D862KA]1526
Failure Code [D8ALKA]1527
Failure Code [D8ALKB]1529
Failure Code [D8AQKR]1531
Failure Code [D8ARKR]1534
Failure Code [D8G1KT]1537
Failure Code [D8G6KT]1538
Failure Code [DAF0MB]1539
Failure Code [DAF0MC]1540
Failure Code [DAF8KB]1541
Failure Code [DAF9KQ]1542
Failure Code [DAFGMC]1543
Failure Code [DAFLKA]1544
Failure Code [DAFLKB]1546
Failure Code [DAFQKR]1548
Failure Code [DAQW00]1549
Failure Code [DAZ9KQ]1550
Failure Code [DAZQKR]1551
Failure Code [DB2QKR]1552
Failure Code [DB2RKR]1559
Failure Code [DBE0KT]1566
Failure Code [DBE0MC]1567
Failure Code [DBE1KK]1568
Failure Code [DBE2KK]1571
Failure Code [DBE2KT]1573
Failure Code [DBE5KK]1574
Failure Code [DBE6KK]1576
Failure Code [DBE7KK]1578
Failure Code [DBE9KQ]1580
Failure Code [DBELKA]1581
Failure Code [DBELKB]1583
Failure Code [DBEQKR]1585
Failure Code [DBERKR]1586
Failure Code [DBR2KT]1589
Failure Code [DD12KA]1590
Failure Code [DD12KB]1592
Failure Code [DD13KA]1594
Failure Code [DD13KB]1596
Failure Code [DD14KA]1598
Failure Code [DD14KB]1600
Failure Code [DDKHKA]1602
Failure Code [DDKHKB]1604
Failure Code [DDN7KA]1606
Failure Code [DDN7KB]1608
Failure Code [DDNLKA]1610
Failure Code [DDNLKB]1612
Failure Code [DGS1KA]1614
Failure Code [DGS1KX]1616
Failure Code [DGT1KA]1618
Failure Code [DGT1KX]1621
Failure Code [DH21KA]1623
Failure Code [DH21KY]1625
Failure Code [DHA4KA]1627
Failure Code [DHAAMA]1629
Failure Code [DHACMA]1631
Failure Code [DK10KA]1633
Failure Code [DK10KB]1636
Failure Code [DK30KA]1638
Failure Code [DK30KX]1641
Failure Code [DK30KY]1642
Failure Code [DK30KZ]1644
Failure Code [DK30L8]1645
Failure Code [DK31KA]1646
Failure Code [DK31KY]1649
Failure Code [DK40KA]1651
Failure Code [DK40KY]1653
Failure Code [DK55KX]1655
Failure Code [DK55KZ]1656
Failure Code [DK55L8]1657
Failure Code [DK56KA]1658
Failure Code [DK56KY]1660
Failure Code [DK57KA]1662
Failure Code [DK57KY]1664
Failure Code [DKH1KA]1666
Failure Code [DKH1KY]1669
Failure Code [DLM3KA]1671
Failure Code [DLM3KB]1673
Failure Code [DLM3MB]1674
Failure Code [DLT3KA]1675
Failure Code [DLT3KB]1677
Failure Code [DR21KX]1679
Failure Code [DR31KX]1680
Failure Code [DV20KB]1681
Failure Code [DW5AKA]1683
Failure Code [DW5AKB]1685
Failure Code [DW5AKY]1687
Failure Code [DW7BKA]1689
Failure Code [DW7BKB]1691
Failure Code [DW7BKY]1693
Failure Code [DWN1KA] (Applicable Machine:25001 to 25152)1694
Failure Code [DWN1KA] (Applicable Machine:25153 and up)1696
Failure Code [DWN1KB] (Applicable Machine:25001 to 25152)1698
Failure Code [DWN1KB] (Applicable Machine:25153 and up)1700
Failure Code [DWN1KY] (Applicable Machine:25001 to 25152)1702
Failure Code [DWN1KY] (Applicable Machine:25153 and up)1704
Failure Code [DWN2KA] (Applicable Machine:25001 to 25152)1706
Failure Code [DWN2KA] (Applicable Machine:25153 and up)1708
Failure Code [DWN2KB] (Applicable Machine:25001 to 25152)1710
Failure Code [DWN2KB] (Applicable Machine:25153 and up)1712
Failure Code [DWN2KY] (Applicable Machine:25001 to 25152)1714
Failure Code [DWN2KY] (Applicable Machine:25153 and up)1715
Failure Code [DWN5KA]1717
Failure Code [DWN5KB]1719
Failure Code [DWN5KY]1720
Failure Code [DXA2KA]1722
Failure Code [DXA2KB]1724
Failure Code [DXA2KY]1726
Failure Code [DXH4KA]1727
Failure Code [DXH4KB]1729
Failure Code [DXH4KY]1731
Failure Code [DXH5KA]1733
Failure Code [DXH5KB]1735
Failure Code [DXH5KY]1736
Failure Code [DXH6KA]1737
Failure Code [DXH6KB]1739
Failure Code [DXH6KY]1741
Failure Code [DXH7KA]1743
Failure Code [DXH7KB]1745
Failure Code [DXH7KY]1747
Failure Code [DXH8KA]1749
Failure Code [DXH8KB]1751
Failure Code [DXH8KY]1753
Failure Code [DXJ4KA]1755
Failure Code [DXJ4KB]1757
Failure Code [F311KA]1759
Failure Code [F311KB]1761
Failure Code [F312KA]1763
Failure Code [F312KB]1765
Failure Code [F313KA]1767
Failure Code [F313KB]1768
Failure Code [F314KA]1769
Failure Code [F314KB]1771
Failure Code [F315KB]1773
Failure Code [F315KY]1775
Failure Code [F316KB]1777
Failure Code [F316KY]1779
Failure Code [F318KB]1781
Failure Code [F318KY]1782
Failure Code [F31AKB]1783
Failure Code [F31AKY]1785
Failure Code [F31BKB]1787
Failure Code [F31BKY]1789
Failure Code [F31CKB]1791
Failure Code [F31CKY]1793
Failure Code [F31DKB]1795
Failure Code [F31DKY]1797
Failure Code [F31EKB]1799
Failure Code [F31EKY]1801
Troubleshooting of Electrical System (E-Mode)1803
E-1 Engine Does Not Start (Engine Does Not Crank)1803
E-2 Manual Preheating System Does Not Operate1810
E-3 Automatic Preheating System Does Not Operate1813
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On1815
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing1817
E-6 When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On1821
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation1822
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation1823
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation1825
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation1826
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation1827
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation1828
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature1829
E-14 DEF Level is Not Shown Correctly1830
E-15 Fuel Level Gauge Does Not Show Correct Level1833
E-16 Power Train Oil Temperature Gauge Does Not Show Correct Temperature1835
E-17 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature1836
E-18 Operation Mode Does Not Change1837
E-19 Gear Shift Mode Does Not Change1838
E-20 Operating Customize Switch Does Not Display Customize Screen1839
E-21 Modifying Setting on Customize Screen Does Not Change Setting of Machine1840
E-22 Some Areas of Machine Monitor Screen are Not Shown1841
E-23 Reverse Slow Mode Does Not Function Correctly1842
E-24 Alarm Buzzer Does Not Sound or Does Not Stop Sounding1843
E-25 Service Meter is Not Shown, While Starting Switch is in OFF Position1844
E-26 Service Mode Cannot be Selected1845
E-27 Horn Does Not Sound1846
E-28 Horn Does Not Stop1848
E-29 Backup Alarm Does Not Sound1849
E-30 Backup Alarm Does Not Stop1851
E-31 Headlamp Does Not Come On1852
E-32 Rear Lamp Does Not Come On1856
E-33 No Wiper Operates1860
E-34 Front Wiper Does Not Operate1864
E-35 Rear Wiper Does Not Operate1867
E-36 Left Door Wiper Does Not Operate1870
E-37 Right Door Wiper Does Not Operate1873
E-38 Front Washer Does Not Operate1876
E-39 Rear Washer Does Not Operate1878
E-40 Left Door Washer Does Not Operate1880
E-41 Right Door Washer Does Not Operate1882
E-42 KOMTRAX System Does Not Operate Correctly1884
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1885
Information Shown in Troubleshooting Table (H-Mode)1885
Failure Mode and Cause Table1886
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull)1892
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed)1894
H-3 Machine Does Not Move Off at All Gear Speeds1895
H-4 Machine Travels Only in One Direction, Forward or in Reverse1897
H-5 Large Time Lag is in Gear Shifting or Directional Change1898
H-6 Brake Does Not Work1900
H-7 Power Train Oil Overheats1901
H-8 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor1903
H-9 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT)1904
H-10 Steering Speed or Power is Not Sufficient1905
H-11 All Work Equipment Operate Slowly1906
H-12 All Work Equipment Do Not Operate1907
H-13 Blade Lift Speed or Power is Low1908
H-14 Blade Tilt Speed or Power is Low1909
H-15 Ripper Lift Speed or Power is Low1910
H-16 Hydraulic Drift of Lifted Blade is Large1911
H-17 Hydraulic Drift of Tilted Blade is Large1912
H-18 Hydraulic Drift of Lifted Ripper is Large1913
H-19 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)1914
H-20 Unusual Noise is Heard from Around Fan1916
Troubleshooting of Engine (S-Mode)1917
Information Shown in Troubleshooting Table (S-Mode)1917
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position1918
S-2 Engine Cranks but No Exhaust Smoke Comes Out1919
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)1920
S-4 Engine Startability is Unsatisfactory1921
S-5 Engine Does Not Pick Up Smoothly1923
S-6 Engine Stops During Operation1925
S-7 Engine Runs Rough or is Not Stable1927
S-8 Engine Lacks Power1928
S-9 KDPF Becomes Clogged in a Short Time1930
S-10 Engine Oil Consumption is Excessive1932
S-11 Oil Becomes Dirty Quickly1933
S-12 Fuel Consumption is Excessive1934
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant1935
S-14 Oil Pressure Drops1936
S-15 Fuel Mixes Into Engine Oil1938
S-16 Water Mixes Into Engine Oil (Milky)1939
S-17 Coolant Temperature Increases Too High (Overheating)1940
S-18 Unusual Noise is Heard1941
S-19 Vibration is Excessive1942
S-20 Air Cannot be Bled from Fuel Circuit1943
S-21 Active Regeneration is Done Frequently1944
S-22 Active Regeneration Continues Long1946
S-23 White Smoke is Exhausted During Active Regeneration1947
S-24 DEF Consumption is Excessive1948
S-25 There is Unusual Smell (Irritating Odor)1950
S-26 Foreign Materials Enter DEF (DEF Increases)1951
50 Disassembly and Assembly1953
Table of Contents1954
Precautions Before Work1959
Related Information on Disassembly and Assembly1960
How to Read This Manual1960
Coating Materials List1961
Special Tool List1966
Sketches of Special Tools1990
Engine and Cooling System1998
Remove and Install Supply Pump Assembly1998
How to Remove Supply Pump Assembly1999
How to Install Supply Pump Assembly2003
Remove and Install Injector Assembly2010
How to Remove Injector Assembly2011
How to Install Injector Assembly2017
Remove and Install Fuel Doser Assembly2028
How to Remove Fuel Doser Assembly2028
How to Install Fuel Doser Assembly2029
Remove and Install Cylinder Head Assembly2031
How to Remove Cylinder Head Assembly2031
How to Install Cylinder Head Assembly2038
Remove and Install EGR Valve Assembly2047
How to Remove EGR Valve Assembly2047
How to Install EGR Valve Assembly2049
Remove and Install EGR Cooler Assembly2052
How to Remove EGR Cooler Assembly2053
How to Install EGR Cooler Assembly2057
Remove and Install Starter Assembly2062
How to Remove Starting Motor Assembly2062
How to Install Starting Motor Assembly2064
Remove and Install Alternator Belt2066
How to Remove Alternator Belt2066
How to Install Alternator Belt2068
Remove and Install Radiator Assembly2070
How to Remove Radiator Assembly2071
How to Install Radiator Assembly2075
Remove and Install Hydraulic Oil Cooler Assembly2081
How to Remove Hydraulic Oil Cooler Assembly2082
How to Install Hydraulic Oil Cooler Assembly2086
Remove and Install Aftercooler Assembly2090
How to Remove Aftercooler Assembly2090
How to Install Aftercooler Assembly2091
Remove and Install Cooling Fan Drive Assembly2092
How to Remove Cooling Fan Drive Assembly2092
How to Install Cooling Fan Drive Assembly2093
Remove and Install Cooling Fan Motor Assembly2096
How to Remove Cooling Fan Motor Assembly2096
How to Install Cooling Fan Motor Assembly2098
Remove and Install Engine Assembly2100
How to Remove Engine Assembly2101
How to Install Engine Assembly2108
Remove and Install Engine Front Oil Seal2114
How to Remove Engine Front Oil Seal2114
How to Install Engine Front Oil Seal2115
Remove and Install Engine Rear Oil Seal2118
How to Remove Engine Rear Oil Seal2118
How to Install Engine Rear Oil Seal2120
Remove and Install Engine Oil Pan2125
How to Remove Engine Oil Pan2125
How to Install Engine Oil Pan2126
Remove and Install Engine Hood Assembly2128
How to Remove Engine Hood Assembly2128
How to Install Engine Hood Assembly2130
Remove and Install Fuel Tank Assembly2132
How to Remove Fuel Tank Assembly2132
How to Install Fuel Tank Assembly2134
Remove and Install DEF Tank Assembly2137
How to Remove DEF Tank Assembly2137
How to Install DEF Tank Assembly2142
Remove and Install DEF Tank Sensor Flange Assembly2146
How to Remove DEF Tank Sensor Flange Assembly2146
How to Install DEF Tank Sensor Flange Assembly2151
Remove and Install DEF Tank Sensor2156
How to Remove DEF Tank Sensor2156
How to Install DEF Tank Sensor2156
Remove and Install DEF Strainer2163
How to Remove DEF Strainer2163
How to Install DEF Strainer2163
Remove and Install DEF Tank Filler Port Filter2164
How to Remove DEF Tank Filler Port Filter2164
How to Install DEF Tank Filler Port Filter2165
Remove and Install KDPF Assembly2167
How to Remove KDPF Assembly2167
How to Install KDPF Assembly2171
Disassemble and Assemble KDPF Assembly2176
How to Disassemble KDPF Assembly2176
How to Assemble KDPF Assembly2180
Remove and Install SCR Assembly2184
How to Remove SCR Assembly2184
How to Install SCR Assembly2187
Remove and Install KDPF and SCR Assembly2190
How to Remove KDPF and SCR Assembly2190
How to Install KDPF and SCR Assembly2200
Remove and Install KCCV Assembly2211
How to Remove KCCV Assembly2211
How to Install KCCV Assembly2214
Remove and Install DEF Mixing Tube2218
How to Remove DEF Mixing Tube2218
How to Install DEF Mixing Tube2221
Remove and Install DEF Injector2227
How to Remove DEF Injector2227
How to Install DEF Injector2230
Remove and Install DEF Pump2233
How to Remove DEF Pump2233
How to Install DEF Pump2236
Remove and Install DEF Hose2240
How to Remove DEF Hose2240
How to Install DEF Hose2245
Remove and Install Air Cleaner Assembly2251
How to Remove Air Cleaner Assembly2251
How to Install Air Cleaner Assembly2252
Remove and Install Air Conditioner Compressor Assembly2253
How to Remove Air Conditioner Compressor Assembly2253
How to Install Air Conditioner Compressor Assembly2255
Power Train2257
Remove and Install Damper Assembly2257
How to Remove Damper Assembly2257
How to Install Damper Assembly2260
Disassemble and Assemble Damper Assembly2263
How to Disassemble Damper Assembly2264
How to Assemble Damper Assembly2265
Remove and Install Power Train Unit Assembly2268
How to Remove Power Train Unit Assembly2268
How to Install Power Train Unit Assembly2273
Disconnect and Connect Power Train Unit Assembly2279
How to Disconnect Power Train Unit Assembly2279
How to Connect Power Train Unit Assembly2284
Disassemble and Assemble PTO Assembly2289
How to Disassemble PTO Assembly2289
How to Assemble PTO Assembly2293
Disassemble and Assemble Torque Converter Assembly2298
How to Disassemble Torque Converter Assembly2298
How to Assemble Torque Converter Assembly2301
Disassemble and Assemble Transmission Assembly2305
How to Disassemble Transmission Assembly2306
How to Assemble Transmission Assembly2314
Disassemble and Assemble HSS Assembly2326
How to Disassemble HSS Assembly2328
How to Assemble HSS Assembly2338
Remove and Install HSS Motor Assembly2356
How to Remove HSS Motor Assembly2356
How to Install HSS Motor Assembly2357
Remove and Install Final Drive Assembly2358
How to Remove Final Drive Assembly2358
How to Install Final Drive Assembly2360
Disassemble and Assemble Final Drive Assembly2362
How to Disassemble Final Drive Assembly2363
How to Assemble Final Drive Assembly2370
Undercarriage and Frame2382
Remove and Install Track Frame Assembly2382
How to Remove Track Frame Assembly2382
How to Install Track Frame Assembly2386
Remove and Install Idler Assembly2390
How to Remove Idler Assembly2390
How to Install Idler Assembly2391
Disassemble and Assemble Idler Assembly2394
How to Disassemble Idler Assembly2394
How to Assemble Idler Assembly2396
Remove and Install Recoil Spring Assembly2400
How to Remove Recoil Spring Assembly2400
How to Install Recoil Spring Assembly2402
Disassemble and Assemble Recoil Spring Assembly2404
How to Disassemble Recoil Spring Assembly2404
How to Assemble Recoil Spring Assembly2408
Remove and Install Track Roller Assembly2411
How to Remove Track Roller Assembly2411
How to Install Track Roller Assembly2413
Disassemble and Assemble Track Roller Assembly2416
How to Disassemble Track Roller Assembly2416
How to Assemble Track Roller Assembly2417
Remove and Install Carrier Roller Assembly2421
How to Remove Carrier Roller Assembly2421
How to Install Carrier Roller Assembly2422
Disassemble and Assemble Carrier Roller Assembly2423
How to Disassemble Carrier Roller Assembly2423
How to Assemble Carrier Roller Assembly2424
Remove and Install Pivot Shaft Assembly2427
How to Remove Pivot Shaft Assembly2427
How to Install Pivot Shaft Assembly2428
Separate and Connect Track Assembly2430
How to Examine Before Separation of Track Assembly2430
How to Separate Track Assembly (Standard)2430
How to Separate Track Assembly (When Track Frame Has Internal Defect)2431
How to Install Track Assembly2433
Separate and Connect PLUS Type Track Assembly2436
Separate PLUS Type Track Assembly Generally2436
Install PLUS Type Track Assembly2436
Disassemble and Assemble Track Assembly Generally2437
How to Disassemble Full Track Shoes Assembly2437
How to Assemble Full Track Shoes Assembly2440
Disassemble and Assemble PLUS Type Track Assembly Generally2453
Disassemble PLUS Type Track Assembly Generally2453
How to Assemble PLUS Type Track Shoes Assembly Generally2454
Disassemble and Assemble One Track Link Assembly in Field2462
How to Disassemble One Track Link Assembly in Field2464
How to Assemble One Track Link Assembly in Field2464
Disassemble and Assemble Master Link2472
How to Disassemble Master Link2473
How to Assemble Master Link2473
Remove and Install Equalizer Bar Assembly2477
How to Remove Equalizer Bar Assembly2477
How to Install Equalizer Bar Assembly2479
Disassemble and Assemble Equalizer Bar Bushing2482
How to Disassemble Equalizer Bar Bushing2482
How to Assemble Equalizer Bar Bushing2483
Open and Close Center Under Guard2484
How to Open Under Guard2484
How to Close Under Guard2485
Remove and Install Center Under Guard Assembly2487
How to Remove Underguard Assembly2487
How to Install Underguard Assembly2494
Hydraulic System2502
Remove and Install Hydraulic Tank Assembly2502
How to Remove Hydraulic Tank Assembly2502
How to Install Hydraulic Tank Assembly2505
Remove and Install Work Equipment Pump and HSS Pump Assembly2509
How to Remove Work Equipment Pump and HSS Pump Assembly2509
How to Install Work Equipment Pump and HSS Pump Assembly2512
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly2514
How to Remove Power Train Pump and Steering Lubrication Pump Assembly2514
How to Install Power Train Pump and Steering Lubrication Pump Assembly2516
Remove and Install Cooling Fan Pump Assembly2518
How to Remove Cooling Fan Pump Assembly2518
How to Install Cooling Fan Pump Assembly2520
Remove and Install Scavenging Pump Assembly2523
How to Remove Scavenging Pump Assembly2523
How to Install Scavenging Pump Assembly2524
Remove and Install Control Valve Assembly2526
How to Remove Control Valve Assembly2526
How to Install Control Valve Assembly2531
Work Equipment2536
Remove and Install Blade Assembly2536
How to Remove Blade Assembly2536
How to Install Blade Assembly2538
Remove and Install Blade Lift Cylinder Assembly2542
How to Remove Blade Lift Cylinder Assembly2543
How to Install Blade Lift Cylinder Assembly2547
Disassemble and Assemble Fixed Multi-Shank Ripper Assembly2552
How to Disassemble Fixed Multi-Shank Ripper Assembly2552
How to Assemble Fixed Multi-Shank Ripper Assembly2554
Disassemble and Assemble Variable Multi-Shank Ripper Assembly2557
How to Disassemble Variable Multi-Shank Ripper Assembly2557
How to Assemble Variable Multi-Shank Ripper Assembly2560
How to Disassemble and Assemble Work Equipment Cylinder Assembly2563
How to Disassemble Work Equipment Cylinder Assembly2564
How to Assemble Work Equipment Cylinder Assembly2567
CAB Related Parts2571
Remove and Install Operator Cab Assembly2571
How to Remove Operator Cab Assembly2571
How to Install Operator Cab Assembly2577
Remove and Install Operator Cab Glass (Adhered Glass)2584
How to Remove Operator Cab Glass (Adhered Glass)2584
How to Install Operator Cab Glass (Adhered Glass)2585
Remove and Install Air Conditioner Unit Assembly2590
How to Remove Air Conditioner Unit Assembly2590
How to Install Air Conditioner Unit Assembly2595
Remove and Install Operator Seat2602
How to Remove Operator Seat2602
How to Install Operator Seat2604
How to Remove and Install Seat Belt2607
How to Remove Seat Belt2607
How to Install Seatbelt2608
Electrical System2609
Remove and Install Engine Controller Assembly2609
How to Remove Engine Controller Assembly2609
How to Install Engine Controller Assembly2611
Remove and Install Power Train Controller Assembly2614
How to Remove Power Train Controller Assembly2614
How to Install Power Train Controller Assembly2615
Remove and Install Machine Monitor Assembly2617
How to Remove Machine Monitor Assembly2617
How to Install Machine Monitor Assembly2618
Remove and Install Mass Air Flow and Temperature Sensor2620
How to Remove Mass Air Flow and Temperature Sensor2620
How to Install Mass Air Flow and Temperature Sensor2621
Remove and Install KCCV Crankcase Pressure Sensor2623
How to Remove KCCV Crankcase Pressure Sensor2623
How to Install KCCV Crankcase Pressure Sensor2625
Remove and Install SCR Temperature Sensor2627
How to Remove SCR Temperature Sensor2627
How to Install SCR Temperature Sensor2629
Remove and Install Gateway Function Controller Assembly2631
How to Remove Gateway Function Controller Assembly2631
How to Install Gateway Function Controller Assembly2634
60 Maintenance Standard2639
Table of Contents2640
Engine and Cooling System2642
Maintenance Standard for Engine Mount2642
Maintenance Standard for Damper2644
Maintenance Standard for Cooling System2646
Maintenance Standard for Cooling Fan Pump2648
Maintenance Standard for Servo Valve2649
Maintenance Standard for Cooling Fan Motor2650
Power Train2652
Maintenance Standard for Universal Joint2652
Maintenance Standard for Power Train Mount2653
Maintenance Standard for Torque Converter and PTO2654
Maintenance Standard for Transmission2657
Maintenance Standard for Transmission ECMV2662
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve2663
Maintenance Standard for Transmission Lubrication Relief Valve2664
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake2665
Maintenance Standard for Brake Valve2669
Maintenance Standard for Final Drive2671
Maintenance Standard for Sprocket for Conventional Type Track Shoes2674
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes2675
Maintenance Standard for Sprocket for PLUS Type Track Shoes2677
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes2678
Undercarriage and Frame2680
Maintenance Standard for Main Frame2680
Maintenance Standard for Suspension2682
Maintenance Standard for Track Frame and Idler Cushion2686
Maintenance Standard for Idler2688
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type)2690
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type)2692
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)2694
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)2696
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes2698
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes2700
Maintenance Standard for Conventional Type Track Shoes2702
Maintenance Standard for PLUS Type Track Shoes2704
Maintenance Standard for Single Shoes and Heavy Duty Shoes2706
Maintenance Standard for Swamp Shoes2707
Hydraulic System2708
Maintenance Standard for Hydraulic Tank2708
Maintenance Standard for Scavenging Pump2709
Maintenance Standard for Steering Lubrication Pump and Power Train Pump2710
Maintenance Standard for Work Equipment and HSS Pump2712
Maintenance Standard for HSS Motor2713
Maintenance Standard for Control Valve2715
Maintenance Standard for Blade PPC Valve2722
Maintenance Standard for Ripper PPC Valve (Fixed Multi-Shank Ripper)2724
Maintenance Standard for Ripper PPC Valve (Variable Multi-Shank Ripper)2726
Maintenance Standard for Quick Drop Valve2729
Maintenance Standard for Work Equipment Lock Solenoid Valve2730
Work Equipment2731
Maintenance Standard for Cylinder Stay2731
Maintenance Standard for Front Work Equipment2732
Maintenance Standard for Cutting Edge and End Bit (Straight Blade and Semi-U Blade2736
Maintenance Standard for Cutting Edge and End Bit (SIGMA Blade)2737
Maintenance Standard for Blade Lift Cylinder2738
Maintenance Standard for Blade Tilt Cylinder2739
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series)2740
Maintenance Standard for Fixed Multi-Shank Ripper2741
Maintenance Standard for Variable Multi-Shank Ripper2744
Maintenance Standard for Ripper Lift Cylinder (Fixed and Variable Multi-Shank Ripper)2747
Maintenance Standard for Ripper Tilt Cylinder (Variable Multi-Shank Ripper)2748
CAB Related Parts2749
Maintenance Standard for CAB Mount2749
80 Appendix2751
Table of Contents2752
Precautions Before Work2754
Air Conditioner System2755
Precautions for Refrigerant2755
Air Conditioner Component2756
Specifications of Air Conditioner2758
Structure and Function of Refrigeration Cycle2759
Outline of Refrigeration Cycle2760
Component Parts of Air Conditioner System2762
Air Conditioner Unit2762
Configuration Diagram of Air Conditioner Unit2762
Function of Air Conditioner Unit2764
Component Parts of Air Conditioner Unit2766
Function of Evaporator as Air Conditioner Unit Component2767
Function of Heater Core as Air Conditioner Unit Component2767
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component2767
Function of Servo Motor as Air Conditioner Unit Component2767
Structure of Expansion Valve as Air Conditioner Unit Component2768
Function of Expansion Valve as Air Conditioner Unit Component2768
Operate Expansion Valve as Air Conditioner Unit Component2768
Function of Dual Pressure Switch2769
Air Conditioner Controller2770
Structure of Air Conditioner Controller2770
Compressor2771
Structure of Compressor2771
Specifications of Compressor2771
Function of Compressor2771
Condenser2772
Structure of Condenser2772
Specifications of Condenser2772
Function of Condenser2772
Structure of Wide Core Condenser2773
Specifications of Wide Core Condenser2773
Function of Wide Core Condenser2773
Receiver Drier2774
Structure of Receiver Dryer2774
Specifications of Receiver Dryer2774
Function of Receiver Dryer2774
Air Conditioner Related Sensors2775
Structure of Sunlight Sensor2775
Function of Sunlight Sensor2775
Structure of Outside Temperature Sensor2775
Function of Outside Air Temperature Sensor2775
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner2777
Circuit Diagram and Configuration of Connector Pins of Air Conditioner2779
System Diagram of Air Conditioner2781
Input and Output Signals of Air Conditioner Controller2782
Function of Air Conditioner Controller2783
Locations of Air Conditioner Parts and Layout of Connectors2784
Examine Air Leakage (Duct)2793
How to Examine Air Leakage (Duct)2793
Explanation for Test of Air Conditioner with Self-Diagnosis Function2796
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor2797
Examine Vent (Mode) Changeover2798
How to Examine Vent (Mode) Changeover2798
Examine Fresh/Recirc Air Changeover2799
How to Examine Fresh/Recirc Air Changeover2799
Examine Sunlight Sensor2800
How to Examine Sunlight Sensor2800
Examine Refrigerant (Dual) Pressure Switch2801
How to Examine Refrigerant (Dual) Pressure Switch2801
Examine Relay2802
How to Examine Relay2802
Air Conditioner Troubleshooting Chart 12803
Air Conditioner Troubleshooting Chart 22804
Information Shown in Troubleshooting Table2807
Failure Code [879AKA]2808
Failure Code [879AKB]2809
Failure Code [879BKA]2810
Failure Code [879BKB]2812
Failure Code [879CKA]2814
Failure Code [879CKB]2815
Failure Code [879DKZ]2816
Failure Code [879EMC]2818
Failure Code [879FMC]2819
Failure Code [879GKX]2820
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)2822
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)2824
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)2828
A-4 Troubleshooting for Fresh/Recirc Air Changeover2830
Troubleshooting by Gauge Pressure2832
Connect Service Tool2835
How to Connect Service Tool2835
Precautions for Disconnection and Connection of Air Conditioner Piping2837
Handle Compressor Oil2839
90 Circuit Diagrams2841
Table of Contents2842
Hydraulic Circuit Diagram2843
Symbols Used in Hydraulic Circuit Diagram2843
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer and Variable Multi-Shank Ripper)2847
Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer and Fixed Multi-Shank Ripper)2849
Hydraulic Circuit Diagram (For Power Tilt Dozer and Variable Multi-Shank Ripper)2851
Hydraulic Circuit Diagram (For Power Tilt Dozer and Fixed Multi-Shank Ripper)2853
Hydraulic Circuit Diagram (For Power Tilt Dozer)2855
Hydraulic Circuit Diagram (For Single Tilt Dozer and Fixed Multi-Shank Ripper)2857
Power Train Hydraulic Circuit Diagram2859
Electrical Circuit Diagram2861
Symbols Used in Electric Circuit Diagram2861
Electrical Circuit Diagram (1/16) (Applicable Machine:25001 to 25152)2865
Electrical Circuit Diagram (2/16) (Applicable Machine:25001 to 25152)2867
Electrical Circuit Diagram (3/16) (Applicable Machine:25001 to 25152)2869
Electrical Circuit Diagram (4/16) (Applicable Machine:25001 to 25152)2871
Electrical Circuit Diagram (5/16) (Applicable Machine:25001 to 25152)2873
Electrical Circuit Diagram (6/16) (Applicable Machine:25001 to 25152)2875
Electrical Circuit Diagram (7/16) (Applicable Machine:25001 to 25152)2877
Electrical Circuit Diagram (8/16) (Applicable Machine:25001 to 25152)2879
Electrical Circuit Diagram (9/16) (Applicable Machine:25001 to 25152)2881
Electrical Circuit Diagram (10/16) (Applicable Machine:25001 to 25152)2883
Electrical Circuit Diagram (11/16) (Applicable Machine:25001 to 25152)2885
Electrical Circuit Diagram (12/16) (Applicable Machine:25001 to 25152)2887
Electrical Circuit Diagram (13/16) (Applicable Machine:25001 to 25152)2889
Electrical Circuit Diagram (14/16) (Applicable Machine:25001 to 25152)2891
Electrical Circuit Diagram (15/16) (Applicable Machine:25001 to 25152)2893
Electrical Circuit Diagram (16/16) (Applicable Machine:25001 to 25152)2895
Electrical Circuit Diagram (1/16) (Applicable Machine:25153 and up)2897
Electrical Circuit Diagram (2/16) (Applicable Machine:25153 and up)2899
Electrical Circuit Diagram (3/16) (Applicable Machine:25153 and up)2901
Electrical Circuit Diagram (4/16) (Applicable Machine:25153 and up)2903
Electrical Circuit Diagram (5/16) (Applicable Machine:25153 and up)2905
Electrical Circuit Diagram (6/16) (Applicable Machine:25153 and up)2907
Electrical Circuit Diagram (7/16) (Applicable Machine:25153 and up)2909
Electrical Circuit Diagram (8/16) (Applicable Machine:25153 and up)2911
Electrical Circuit Diagram (9/16) (Applicable Machine:25153 and up)2913
Electrical Circuit Diagram (10/16) (Applicable Machine:25153 and up)2915
Electrical Circuit Diagram (11/16) (Applicable Machine:25153 and up)2917
Electrical Circuit Diagram (12/16) (Applicable Machine:25153 and up)2919
Electrical Circuit Diagram (13/16) (Applicable Machine:25153 and up)2921
Electrical Circuit Diagram (14/16) (Applicable Machine:25153 and up)2923
Electrical Circuit Diagram (15/16) (Applicable Machine:25153 and up)2925
Electrical Circuit Diagram (16/16) (Applicable Machine:25153 and up)2927
Index2929
IMAGES PREVIEW OF THE MANUAL:
S.M 28/12/24
