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kOMATSU D155AX-7 BULLDOZER SERVICE REPAIR MANUAL (SEN05653-02) – PDF DOWNLOAD
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- KOMATSU D155AX-7 BULLDOZER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEN05653-02
- SERIAL NUMBERS 90001 and up
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Description
kOMATSU D155AX-7 BULLDOZER SERVICE REPAIR MANUAL (SEN05653-02)
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KOMATSU D155AX-7 BULLDOZER SERVICE REPAIR MANUAL (SEN05653-02) – PDF DOWNLOAD:
Description:
kOMATSU D155AX-7 BULLDOZER SERVICE REPAIR MANUAL (SEN05653-02)
• This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
• This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
• This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting
• This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes.
50. Disassembly and assembly
• This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
• This section gives maintenance standard values of each component. The maintenance standard subsection explains the criteria and remedies for disassembly and service.
80. Appendix
• The section contains the equipment which can not be class, field in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment.
90 Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Table of Contents:
kOMATSU D155AX-7 BULLDOZER SERVICE REPAIR MANUAL (SEN05653-02)
COVER................................................................................................................................... 1 00 Index and foreword .................................................................................................................. 3 Index .............................................................................................................................. 4 Foreword, safety and general information ........................................................................................... 19 Important safety notice ........................................................................................................ 19 How to read the shop manual .................................................................................................... 26 Explanation of terms for maintenance standard .................................................................................. 28 Handling of fuel system devices ................................................................................................ 30 Handling of intake system parts ................................................................................................ 31 Handling of hydraulic equipment ................................................................................................ 32 Method of disconnecting and connecting push-pull type coupler .................................................................. 34 Handling of electrical equipment ............................................................................................... 37 How to read electric wire code ................................................................................................. 45 Precautions when performing operation .......................................................................................... 48 Practical use of KOMTRAX ....................................................................................................... 51 Standard tightening torque table ............................................................................................... 52 List of abbreviation ........................................................................................................... 56 Conversion table ............................................................................................................... 60 01 Specification ....................................................................................................................... 65 Table of contents .................................................................................................................. 66 Specifications ..................................................................................................................... 67 Specification drawing .......................................................................................................... 67 Specification .................................................................................................................. 69 Weight table ................................................................................................................... 77 Table of fuel, coolant, and lubricants ......................................................................................... 79 10 Structure and function .............................................................................................................. 81 Table of contents .................................................................................................................. 82 Engine and cooling system .......................................................................................................... 84 Engine related parts ........................................................................................................... 84 KVGT ........................................................................................................................... 86 EGR system piping drawing ...................................................................................................... 92 EGR system circuit diagram ..................................................................................................... 94 EGR valve ...................................................................................................................... 95 EGR cooler ..................................................................................................................... 97 KCCV layout drawing ............................................................................................................ 99 KCCV ventilator ................................................................................................................ 101 KDPF ........................................................................................................................... 103 Damper ......................................................................................................................... 107 Cooling system ................................................................................................................. 109 Cooling fan pump ............................................................................................................... 112 Cooling fan motor .............................................................................................................. 122 Power train ........................................................................................................................ 130 Power train system ............................................................................................................. 130 HSS system ..................................................................................................................... 133 Overall drawing of power train unit ............................................................................................ 135 Power train mount .............................................................................................................. 137 Layout of power train hydraulic piping ......................................................................................... 139 Transmission, steering, and brake control ...................................................................................... 141 Universal joint ................................................................................................................ 143 Torque converter and PTO ....................................................................................................... 144 Torque converter control valve ................................................................................................. 152 Lockup clutch ECMV ............................................................................................................. 153 Stator clutch ECMV ............................................................................................................. 158 Transmission ................................................................................................................... 162 Transmission ECMV .............................................................................................................. 176 Main relief valve and torque converter relief valve ............................................................................ 184 Transmission lubrication relief valve .......................................................................................... 186 Bevel gear shaft, HSS, and brake ............................................................................................... 187 Brake control valve ............................................................................................................ 205 Brake ECMV ..................................................................................................................... 208 Brake solenoid valve ........................................................................................................... 212 Sudden stop prevention valve ................................................................................................... 214 Final drive .................................................................................................................... 216 Undercarriage and frame ............................................................................................................ 219 Main frame ..................................................................................................................... 219 Suspension ..................................................................................................................... 221 Track frame and idler cushion .................................................................................................. 223 Hydraulic system ................................................................................................................... 225 Hydraulic piping drawing ....................................................................................................... 225 Work equipment control ......................................................................................................... 228 Hydraulic tank ................................................................................................................. 231 CLSS ........................................................................................................................... 233 Scavenging pump ................................................................................................................ 236 Steering lubrication pump and power train pump ................................................................................. 237 Work equipment and HSS pump .................................................................................................... 239 HSS motor ...................................................................................................................... 263 Control valve .................................................................................................................. 271 Quick drop valve ............................................................................................................... 309 Work equipment lock solenoid valve ............................................................................................. 314 Hydraulic oil cooler bypass valve .............................................................................................. 315 Accumulator .................................................................................................................... 316 Self-pressure reducing valve ................................................................................................... 318 Work equipment ..................................................................................................................... 325 Cylinder stay .................................................................................................................. 325 Blade .......................................................................................................................... 326 Ripper ......................................................................................................................... 327 Piston valve ................................................................................................................... 329 Cab and its attachments ............................................................................................................ 330 ROPS cab ....................................................................................................................... 330 Function ....................................................................................................................... 331 Cab mount ...................................................................................................................... 332 Electrical system .................................................................................................................. 333 Engine control ................................................................................................................. 333 Engine control system .......................................................................................................... 334 Palm command control system .................................................................................................... 335 System operating lamp function ................................................................................................. 339 Battery disconnect switch function ............................................................................................. 341 Machine monitor system ......................................................................................................... 342 KOMTRAX system ................................................................................................................. 365 System component parts ......................................................................................................... 367 Sensor ......................................................................................................................... 385 20 Standard value tables ............................................................................................................... 399 Table of contents .................................................................................................................. 400 Standard service value table ....................................................................................................... 401 Standard value table for engine ................................................................................................ 401 Standard value table for machine ............................................................................................... 402 Standard value table for electrical system ..................................................................................... 411 30 Testing and adjusting ............................................................................................................... 421 Table of contents .................................................................................................................. 422 General information on testing and adjusting ....................................................................................... 424 Tools for testing and adjusting ................................................................................................ 424 Sketch of tools for testing and adjusting ...................................................................................... 427 Engine and cooling system .......................................................................................................... 428 Testing engine speed ........................................................................................................... 428 Measuring boost pressure ....................................................................................................... 430 Measuring exhaust gas temperature .............................................................................................. 432 Measuring exhaust gas color .................................................................................................... 435 Adjusting valve clearance ...................................................................................................... 437 Measuring compression pressure ................................................................................................. 439 Measuring blowby pressure ...................................................................................................... 442 Measuring engine oil pressure .................................................................................................. 443 Measuring EGR valve and KVGT driving oil pressure .............................................................................. 444 Measuring fuel pressure ........................................................................................................ 446 Measuring fuel delivery, return and leakage .................................................................................... 447 Bleeding air from fuel system .................................................................................................. 450 Checking fuel circuit for leakage .............................................................................................. 452 Handling cylinder cutout mode operation ........................................................................................ 453 Handling no injection cranking operation ....................................................................................... 454 Replacing belt for alternator and air conditioner compressor, adjusting belt tension ........................................... 455 Adjusting fuel control dial and decelerator pedal .............................................................................. 456 Procedures for cleaning fuel doser ............................................................................................. 458 Writing compensation values at replacement of injector and engine controller ................................................... 461 Power train ........................................................................................................................ 465 Measuring power train oil pressure ............................................................................................. 465 Adjusting transmission output shaft speed sensor (replacement procedure) ....................................................... 472 Simple test procedure for brake performance .................................................................................... 473 Adjusting brake pedal .......................................................................................................... 474 Adjusting parking brake lever .................................................................................................. 476 Retrieval of disabled machine by using brake release device .................................................................... 478 Undercarriage and frame ............................................................................................................ 481 Adjusting idler clearance ...................................................................................................... 481 Checking and adjusting track shoe tension ...................................................................................... 482 Hydraulic system ................................................................................................................... 483 Releasing remaining pressure in work equipment cylinder ........................................................................ 483 Measuring and adjusting work equipment and HSS oil pressures ................................................................... 484 Measuring source pressure of control circuit ................................................................................... 488 Measuring work equipment lock solenoid valve output pressure ................................................................... 489 Isolating the parts causing hydraulic drift in blade and ripper ................................................................ 490 Checking fan speed ............................................................................................................. 491 Measuring fan circuit oil pressure ............................................................................................. 492 Bleeding air from fan pump ..................................................................................................... 494 Measuring internal oil leakage of work equipment cylinder ...................................................................... 495 Bleeding air from work equipment cylinders ..................................................................................... 496 Emergency operating method when work equipment has trouble ..................................................................... 497 Measuring ripper pin puller solenoid valve output pressure ..................................................................... 499 Work equipment ..................................................................................................................... 500 Adjusting work equipment lock lever ............................................................................................ 500 Adjusting blade ................................................................................................................ 502 Cab and its attachments ............................................................................................................ 504 Adjusting operator's cab ....................................................................................................... 504 Electrical system .................................................................................................................. 507 Special functions of machine monitor ........................................................................................... 507 Angle adjustment of rear view camera ........................................................................................... 585 Handling voltage circuit of engine controller .................................................................................. 586 Handling battery disconnect switch ............................................................................................. 587 Testing diodes ................................................................................................................. 588 Pm clinic .......................................................................................................................... 589 Pm Clinic service .............................................................................................................. 589 Check sheet .................................................................................................................... 594 40 Troubleshooting ..................................................................................................................... 601 Table of contents .................................................................................................................. 602 General information on troubleshooting ............................................................................................. 611 Troubleshooting points ......................................................................................................... 611 Sequence of events in troubleshooting .......................................................................................... 613 Checks before troubleshooting .................................................................................................. 615 Inspection procedure before troubleshooting .................................................................................... 617 Classification and procedures for troubleshooting .............................................................................. 634 Symptom and troubleshooting numbers ............................................................................................ 636 Information in troubleshooting table ........................................................................................... 639 Connector list and layout ...................................................................................................... 641 Connector contact identification ............................................................................................... 655 T-branch box and T-branch adapter table ........................................................................................ 692 Fuse location table ............................................................................................................ 698 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement .................................................................. 702 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................ 705 Fabrication of short-circuit connector (for CA1883 and CA3135) ................................................................. 706 Failure codes table ............................................................................................................ 707 Troubleshooting by failure code (Display of code) .................................................................................. 721 Failure code [1500L0] Transmission clutch: Abnormal ............................................................................ 721 Failure code [15SAL1] Forward clutch: Fill High ................................................................................ 722 Failure code [15SALH] Forward clutch: Fill Low ................................................................................. 724 Failure code [15SBL1] Reverse clutch: Fill High ................................................................................ 726 Failure code [15SBLH] Reverse clutch: Fill Low ................................................................................. 728 Failure code [15SEL1] Speed 1st clutch: Fill High .............................................................................. 730 Failure code [15SELH] Speed 1st clutch: Fill Low ............................................................................... 732 Failure code [15SFL1] Speed 2nd clutch: Fill High .............................................................................. 734 Failure code [15SFLH] Speed 2nd clutch: Fill Low ............................................................................... 736 Failure code [15SGL1] Speed 3rd clutch: Fill High .............................................................................. 738 Failure code [15SGLH] Speed 3rd clutch: Fill Low ............................................................................... 740 Failure code [15SJL1] L/U: Fill High ........................................................................................... 742 Failure code [15SJLH] L/U: Fill Low ............................................................................................ 744 Failure code [1800MW] P/T clutch:Slip .......................................................................................... 746 Failure code [2300NR] Brake Thermal Load Abnormality ........................................................................... 747 Failure code [2301L1] Right brake: Fill High ................................................................................... 748 Failure code [2301LH] Right brake: Fill low .................................................................................... 750 Failure code [2302L1] Left brake: Fill High .................................................................................... 752 Failure code [2302LH] Left brake: Fill low ..................................................................................... 754 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................ 756 Failure code [879AKB] A/C Inner Sensor Short Circuit ........................................................................... 757 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................ 758 Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................................... 759 Failure code [879CKA] Ventilating Sensor Open Circuit .......................................................................... 760 Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................................... 761 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit .................................................................... 762 Failure code [879EMC] Ventilation Damper Abnormality ........................................................................... 763 Failure code [879FMC] Air Mix Damper Abnormality ............................................................................... 764 Failure code [879GKX] Refrigerant Abnormality .................................................................................. 765 Failure code [989L00] Engine Controller Lock Caution 1 ......................................................................... 766 Failure code [989M00] Engine Controller Lock Caution 2 ......................................................................... 767 Failure code [989N00] Engine Controller Lock Caution 3 ......................................................................... 768 Failure code [A1U0N3] HC Desorb Request 1 ...................................................................................... 769 Failure code [A1U0N4] HC Desorb Request 2 ...................................................................................... 771 Failure code [AA10NX] Air Cleaner Clogging ..................................................................................... 773 Failure code [AB00KE] Charge Voltage Low ....................................................................................... 775 Failure code [B@BAZG] Eng Oil Press Low ........................................................................................ 776 Failure code [B@BCNS] Eng Water Overheat ....................................................................................... 777 Failure code [B@CENS] P/L Oil Overheat ......................................................................................... 778 Failure code [B@BCZK] Eng Water Level Low ...................................................................................... 779 Failure code [B@HANS] Hyd Oil Overheat ......................................................................................... 781 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 782 Failure code [CA122] Chg Air Press Sensor High Error ........................................................................... 783 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................ 785 Failure code [CA131] Throttle Sensor High Error ................................................................................ 787 Failure code [CA132] Throttle Sensor Low Error ................................................................................. 789 Failure code [CA135] Eng Oil Press Sensor High Error ........................................................................... 791 Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................ 793 Failure code [CA144] Coolant Temp Sens High Error .............................................................................. 795 Failure code [CA145] Coolant Temp Sens Low Error ............................................................................... 797 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................ 799 Failure code [CA154] Chg Air Temp Sensor Low Error ............................................................................. 801 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................ 803 Failure code [CA221] Ambient Press Sens High Error ............................................................................. 805 Failure code [CA222] Ambient Press Sens Low Error .............................................................................. 807 Failure code [CA227] Sensor 2 Supply Volt High Error ........................................................................... 809 Failure code [CA234] Eng Overspeed ............................................................................................. 810 Failure code [CA238] Ne Speed Sensor Supply Volt Error ......................................................................... 811 Failure code [CA239] Ne Speed Sens Supply Volt High Error ...................................................................... 812 Failure code [CA271] IMV/PCV1 Short Error ...................................................................................... 813 Failure code [CA272] IMV/PCV1 Open Error ....................................................................................... 814 Failure code [CA273] PCV2 Short Error .......................................................................................... 815 Failure code [CA274] PCV2 Open Error ........................................................................................... 816 Failure code [CA322] Inj #1(L#1) Open/Short Error .............................................................................. 817 Failure code [CA323] Inj #5(L#5) Open/Short Error .............................................................................. 819 Failure code [CA324] Inj #3(L#3) Open/Short Error .............................................................................. 821 Failure code [CA325] Inj #6(L#6) Open/Short Error .............................................................................. 823 Failure code [CA331] Inj #2(L#2) Open/Short Error .............................................................................. 825 Failure code [CA332] Inj #4(L#4) Open/Short Error .............................................................................. 827 Failure code [CA343] ECM Critical Internal Failure ............................................................................. 829 Failure code [CA351] Injectors Drive Circuit Error ............................................................................. 830 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................ 831 Failure code [CA356] Mass Air Flow Sensor High Error ........................................................................... 833 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................ 835 Failure code [CA386] Sensor 1 Supply Volt High Error ........................................................................... 837 Failure code [CA441] Battery Voltage Low Error ................................................................................. 838 Failure code [CA442] Battery Voltage High Error ................................................................................ 841 Failure code [CA449] Rail Press Very High Error ................................................................................ 842 Failure code [CA451] Rail Press Sensor High Error .............................................................................. 843 Failure code [CA452] Rail Press Sensor Low Error ............................................................................... 845 Failure code [CA515] Rail Press Sens Sup Volt High Error ....................................................................... 847 Failure code [CA516] Rail Press Sens Sup Volt Low Error ........................................................................ 849 Failure code [CA553] Rail Press High Error ..................................................................................... 851 Failure code [CA555] Crankcase Press High Error 2 .............................................................................. 852 Failure code [CA556] Crankcase Press High Error 3 .............................................................................. 853 Failure code [CA559] Rail Press Low Error ...................................................................................... 854 Failure code [CA595] Turbo Speed High Error 2 .................................................................................. 858 Failure code [CA687] Turbo Speed Low Error ..................................................................................... 859 Failure code [CA689] Eng Ne Speed Sensor Error ................................................................................. 861 Failure code [CA691] Intake Air Temp Sens High Error ........................................................................... 863 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................ 865 Failure code [CA697] ECM Internal Temp Sensor High Error ....................................................................... 867 Failure code [CA698] ECM Int Temp Sensor Low Error ............................................................................. 868 Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 869 Failure code [CA778] Eng Bkup Speed Sensor Error ............................................................................... 870 Failure code [CA1117] Persistent Data Lost Error ............................................................................... 872 Failure code [CA1664] KDOC Malfunction ......................................................................................... 873 Failure code [CA1691] Regeneration Ineffective ................................................................................. 876 Failure code [CA1695] Sensor 5 Supply Volt High Error .......................................................................... 879 Failure code [CA1696] Sensor 5 Supply Volt Low Error ........................................................................... 881 Failure code [CA1843] Crankcase Press Sens High Error .......................................................................... 883 Failure code [CA1844] Crankcase Press Sens Low Error ........................................................................... 885 Failure code [CA1879] KDPF Delta P Sensor High Error ........................................................................... 887 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................ 889 Failure code [CA1883] KDPF Delta P Sens In Range Error ......................................................................... 891 Failure code [CA1921] KDPF Soot Load High Error 1 .............................................................................. 895 Failure code [CA1922] KDPF Soot Load High Error 2 .............................................................................. 898 Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................................... 902 Failure code [CA1924] Dosing Fuel Valve 1 Low Error ............................................................................ 904 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ....................................................................... 907 Failure code [CA1927] Dosing Fuel Press Sens High Error ........................................................................ 909 Failure code [CA1928] Dosing Fuel Press Sens Low Error ......................................................................... 911 Failure code [CA1942] Crankcase Press Sens In Range Error ...................................................................... 913 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error .......................................................................... 914 Failure code [CA1977] Fuel Doser Open/Short Error .............................................................................. 916 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................ 918 Failure code [CA2185] Throt Sensor Sup Volt High Error ......................................................................... 920 Failure code [CA2186] Throt Sensor Sup Volt Low Error .......................................................................... 922 Failure code [CA2249] Rail Press Very Low Error ................................................................................ 924 Failure code [CA2265] Fuel Feed Pump Open Error ................................................................................ 925 Failure code [CA2266] Fuel Feed Pump Short Error ............................................................................... 927 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................ 929 Failure code [CA2272] EGR Valve Pos Sens Low Error ............................................................................. 931 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................ 933 Failure code [CA2353] EGR Valve Solenoid Short Error ........................................................................... 935 Failure code [CA2357] EGR Valve Servo Error .................................................................................... 937 Failure code [CA2381] KVGT Pos Sens High Error ................................................................................. 938 Failure code [CA2382] KVGT Pos Sens Low Error .................................................................................. 940 Failure code [CA2383] KVGT Solenoid Open Error ................................................................................. 942 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................ 944 Failure code [CA2387] KVGT Servo Error ......................................................................................... 946 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................ 947 Failure code [CA2556] Grid Htr Relay Volt High Error ........................................................................... 949 Failure code [CA2637] KDOC Face Plugging ....................................................................................... 951 Failure code [CA2639] Manual Stationary Regeneration Request ................................................................... 953 Failure code [CA2732] Dosing Fuel Valve 2 High Error ........................................................................... 955 Failure code [CA2733] Dosing Fuel Valve 2 Low Error ............................................................................ 957 Failure code [CA2741] Dosing Fuel Valve Swap Error ............................................................................. 959 Failure code [CA2765] Inj Trim Data Error ...................................................................................... 960 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error .......................................................................... 961 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ......................................................................... 964 Failure code [CA3133] KDPF Outlet Press Sens High Error ........................................................................ 967 Failure code [CA3134] KDPF Outlet Press Sens Low Error ......................................................................... 969 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .................................................................... 971 Failure code [CA3251] KDOC Inlet Temp High Error ............................................................................... 975 Failure code [CA3253] KDOC Temp Error - Non Regeneration ....................................................................... 978 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................ 981 Failure code [CA3255] KDPF Temp Error - Non Regeneration ....................................................................... 984 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................ 987 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................ 990 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................ 993 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ......................................................................... 996 Failure code [CA3314] KDOC Inlet Temp Sens High Error .......................................................................... 999 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ......................................................................1003 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ..........................................................................1008 Failure code [CA3317] KDOC Outlet Temp Sens High Error .........................................................................1011 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .....................................................................1015 Failure code [CA3319] KDPF Outlet Temp Sens High Error .........................................................................1020 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ..........................................................................1024 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error .....................................................................1027 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .................................................................1032 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ..................................................................1034 Failure code [D130KA] Neutral relay:Open .......................................................................................1036 Failure code [D130KB] Neutral relay:Short circuit ..............................................................................1038 Failure code [D190KA] ECM ACC signal HOLD relay: Open ..........................................................................1040 Failure code [D190KB] ECM ACC signal HOLD relay: Short circuit .................................................................1042 Failure code [D19JKZ] Personal Code Relay Abnormality ..........................................................................1044 Failure code [D811MC] KOMTRAX Error ............................................................................................1047 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................1048 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ....................................................................1049 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................................................1051 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....................................................................................1053 Failure code [DAF0MB] Monitor ROM Abnormality ..................................................................................1054 Failure code [DAF0MC] Monitor Error ............................................................................................1055 Failure code [DAF8KB] Camera Power Supply Short Circuit ........................................................................1056 Failure code [DAF9KQ] Model Selection Abnormality ..............................................................................1057 Failure code [DAFGMC] GPS Module Error .........................................................................................1058 Failure code [DAFLKA] Operating Lamp Open Circuit (Mon) ........................................................................1059 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ...................................................................1061 Failure code [DAFQKR] CAN2 Discon (Monitor) ....................................................................................1063 Failure code [DAZ9KQ] A/C Model Selection Abnormality ..........................................................................1064 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .................................................................................1065 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................1066 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................1071 Failure code [DB90KT] WE controller: Abnormality in controller .................................................................1077 Failure code [DB90MC] WE Con Error .............................................................................................1078 Failure code [DB91KK] WE controller:Source voltage low .........................................................................1079 Failure code [DB92KK] WE controller: Output voltage low ........................................................................1082 Failure code [DB95KK] WE:Sensor volt 5V (0) Out of normal range ................................................................1084 Failure code [DB97KK] WE: Sensor volt 5V (1) Out of normal range ...............................................................1086 Failure code [DB99KQ] WE controller: Type select signal ........................................................................1088 Failure code [DB9LKA] Operating Lamp Open Circuit (WE Con) .....................................................................1089 Failure code [DB9LKB] Operating Lamp Short Circuit (WE Con) ....................................................................1091 Failure code [DB9QKR] CAN2 Discon (WE Con) .....................................................................................1093 Failure code [DB9RKR] CAN1 Discon (WE Con) .....................................................................................1094 Failure code [DBE0KT] PT controller: Abnormality in controller .................................................................1096 Failure code [DBE1KK] PT controller:Source voltage low .........................................................................1097 Failure code [DBE2KK] PT controller: Output voltage low ........................................................................1099 Failure code [DBE5KK] PT:Sensor volt 5V (0) Out of normal range ................................................................1101 Failure code [DBE6KK] PT: Sensor volt 24 V Out of normal range .................................................................1103 Failure code [DBE9KQ] PT controller: Type select signal ........................................................................1105 Failure code [DBELKA] Operating Lamp Open Circuit (PT Con) .....................................................................1106 Failure code [DBELKB] Operating Lamp Short Circuit (PT Con) ....................................................................1108 Failure code [DBEQKR] CAN2 Discon (PT Con) .....................................................................................1110 Failure code [DBERKR] CAN1 Discon (PT Con) .....................................................................................1111 Failure code [DD12KA] Shift up Sw: Open ........................................................................................1113 Failure code [DD12KB] Shift up SW: Short Circuit ...............................................................................1115 Failure code [DD13KA] Shift down SW: Open ......................................................................................1117 Failure code [DD13KB] Shift down SW: Short Circuit .............................................................................1119 Failure code [DD14KA] Parking lever SW: Open ...................................................................................1121 Failure code [DD14KB] Parking lever SW: Short circuit ..........................................................................1123 Failure code [DDDDKA] Brake pedal SW: Open .....................................................................................1125 Failure code [DDDDKB] Brake pedal SW: Short circuit ............................................................................1127 Failure code [DDDDKX] Brake pedal Sw: Mismatch .................................................................................1129 Failure code [DDKAKA] Blade float Sw:Open ......................................................................................1130 Failure code [DDKAKB] Blade float Sw:Short circuit .............................................................................1132 Failure code [DDKBKA] Blade auto pitch Sw:Open .................................................................................1134 Failure code [DDKBKB] Blade auto pitch Sw:Short circuit ........................................................................1136 Failure code [DDKCL4] Ripper tilt in Sw:Signal mismatch ........................................................................1138 Failure code [DDKEL4] Ripper tilt back Sw:Signal mismatch ......................................................................1140 Failure code [DDN7L4] Blade pitch back Sw:Signal mismatch ......................................................................1142 Failure code [DDN8L4] Blade pitch dump Sw:Signal mismatch ......................................................................1144 Failure code [DDNLKA] Weq lock Sw:Open .........................................................................................1146 Failure code [DDNLKB] Weq lock Sw:Short circuit ................................................................................1148 Failure code [DDTSL1] S/C :Fill High ...........................................................................................1150 Failure code [DDTSLH] S/C :Fill Low ............................................................................................1152 Failure code [DFA4KX] Blade lift lever:Main and Sub Error ......................................................................1154 Failure code [DFA4KZ] Blade lift lever:Main and Sub Error ......................................................................1155 Failure code [DFA4L8] Blade lift lever:Signal mismatch .........................................................................1156 Failure code [DFA5KA] Blade lift lever1:Open ...................................................................................1157 Failure code [DFA5KB] Blade lift lever1:Hot Short ..............................................................................1159 Failure code [DFA6KA] Blade lift lever2:Open ...................................................................................1161 Failure code [DFA6KB] Blade lift lever2:Hot Short ..............................................................................1163 Failure code [DFA7KX] Blade tilt lever:Main and Sub Error ......................................................................1165 Failure code [DFA7KZ] Blade tilt lever:Main and Sub Error ......................................................................1166 Failure code [DFA7L8] Blade tilt lever:Signal mismatch .........................................................................1167 Failure code [DFA8KA] Blade tilt lever1:Open ...................................................................................1168 Failure code [DFA8KB] Blade tilt lever1:Hot Short ..............................................................................1170 Failure code [DFA9KA] Blade tilt lever2:Open ...................................................................................1172 Failure code [DFA9KB] Blade tilt lever2:Hot Short ..............................................................................1175 Failure code [DFAAKX] Ripper lift lever:Main and Sub Error .....................................................................1177 Failure code [DFAAKZ] Ripper lift lever:Main and Sub Error .....................................................................1178 Failure code [DFAAL8] Ripper lift lever:Signal mismatch ........................................................................1179 Failure code [DFABKA] Ripper lift lever1:Open ..................................................................................1180 Failure code [DFABKB] Ripper lift lever1:Hot Short .............................................................................1182 Failure code [DFACKA] Ripper lift lever2:Open ..................................................................................1184 Failure code [DFACKB] Ripper lift lever2:Hot Short .............................................................................1187 Failure code [DGS1KA] Hyd oil temp sensor:Open .................................................................................1189 Failure code [DGS1KX] Hyd oil temp:Out of normal range .........................................................................1191 Failure code [DGT1KA] T/C oil temp sensor:Open .................................................................................1192 Failure code [DGT1KX] T/C oil temp sensor:Out of normal range ..................................................................1194 Failure code [DH21KA] Weq pressure sensor:Open .................................................................................1196 Failure code [DH21KB] Weq pressure sensor:Hot Short ............................................................................1198 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .....................................................................1200 Failure code [DHT5KA] T/C in-pressure sensor:Open ..............................................................................1201 Failure code [DHT5KB] T/C in-pressure sensor:Hot Short .........................................................................1203 Failure code [DHT7KA] T/C out-pressure sensor:Open .............................................................................1205 Failure code [DHT7KB] T/C out-pressure sensor:Hot Short ........................................................................1207 Failure code [DK10KA] Fuel control Dial:Open ...................................................................................1209 Failure code [DK10KB] Fuel control Dial:Short circuit ..........................................................................1212 Failure code [DK30KA] ST lever1:Open ...........................................................................................1214 Failure code [DK30KB] ST lever1:Hot Short ......................................................................................1216 Failure code [DK30KX] ST lever:Main and Sub Error ..............................................................................1218 Failure code [DK30KZ] ST lever:Main and Sub Error ..............................................................................1219 Failure code [DK30L8] ST lever:Signal mismatch .................................................................................1220 Failure code [DK31KA] ST lever2:Open ...........................................................................................1221 Failure code [DK31KB] ST lever2:Hot Short ......................................................................................1223 Failure code [DK40KA] Brake potentiometer:Open .................................................................................1225 Failure code [DK40KB] Brake potentiometer:Hot Short ............................................................................1227 Failure code [DK55KX] FR lever:Main and Sub Error ..............................................................................1229 Failure code [DK55KZ] FR lever:Main and Sub Error ..............................................................................1230 Failure code [DK55L8] FR lever:Signal mismatch .................................................................................1231 Failure code [DK56KA] FR lever1:Open ...........................................................................................1232 Failure code [DK56KB] FR lever1:Hot Short ......................................................................................1234 Failure code [DK57KA] FR lever2:Open ...........................................................................................1236 Failure code [DK57KB] FR lever2:Hot Short ......................................................................................1238 Failure code [DKH1KA] Pitch angle sensor:Open ..................................................................................1240 Failure code [DKH1KB] Pitch angle sensor:Hot Short .............................................................................1242 Failure code [DLM3KA] Fan rev. sensor:Open .....................................................................................1244 Failure code [DLM3MB] Fan control:Mismatch .....................................................................................1245 Failure code [DLT3KA] T/M out-speed sensor:Open ................................................................................1246 Failure code [DLT3KB] T/M out-speed sensor:Short circuit .......................................................................1248 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ..................................................................1249 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ..................................................................1250 Failure code [DV20KB] Back-up alarm :Short circuit .............................................................................1251 Failure code [DW7BKA] Fan Reverse Solenoid Open Circuit ........................................................................1252 Failure code [DW7BKB] Fan Reverse Solenoid Short Circuit .......................................................................1254 Failure code [DWN1KA] Hss EPC RH:Open ..........................................................................................1255 Failure code [DWN1KB] Hss EPC RH:Short circuit .................................................................................1257 Failure code [DWN1KY] Hss EPC RH:Hot short .....................................................................................1258 Failure code [DWN2KA] Hss EPC LH:Open ..........................................................................................1259 Failure code [DWN2KB] Hss EPC LH:Short circuit .................................................................................1261 Failure code [DWN2KY] Hss EPC LH:Hot short .....................................................................................1262 Failure code [DWN3KA] S.S.P.V. solenoid:Open ...................................................................................1263 Failure code [DWN3KB] S.S.P.V. solenoid:Short circuit ..........................................................................1265 Failure code [DWN3KY] S.S.P.V. solenoid:Hot short ..............................................................................1266 Failure code [DWN5KA] Fan pump solenoid 1:Open .................................................................................1267 Failure code [DWN5KB] Fan pump solenoid 1:Short circuit ........................................................................1268 Failure code [DWN5KY] Fan pump solenoid 1:Hot Short ............................................................................1269 Failure code [DXA2KA] TVC solenoid 1:Open ......................................................................................1271 Failure code [DXA2KB] TVC solenoid 1:Short circuit .............................................................................1273 Failure code [DXA2KY] TVC solenoid 1:Hot short .................................................................................1274 Failure code [DXH1KA] Lock-up ECMV:Open ........................................................................................1275 Failure code [DXH1KB] Lock-up ECMV:Short circuit ...............................................................................1277 Failure code [DXH1KY] Lock-up ECMV:Hot short ...................................................................................1278 Failure code [DXH4KA] 1st clutch ECMV:Open .....................................................................................1280 Failure code [DXH4KB] 1st clutch ECMV:Short circuit ............................................................................1282 Failure code [DXH4KY] 1st clutch ECMV:Hot short ................................................................................1284 Failure code [DXH5KA] 2nd clutch ECMV:Open .....................................................................................1286 Failure code [DXH5KB] 2nd clutch ECMV:Short circuit ............................................................................1287 Failure code [DXH5KY] 2nd clutch ECMV:Hot short ................................................................................1288 Failure code [DXH6KA] 3rd clutch ECMV:Open .....................................................................................1290 Failure code [DXH6KB] 3rd clutch ECMV:Short circuit ............................................................................1291 Failure code [DXH6KY] 3rd clutch ECMV:Hot short ................................................................................1292 Failure code [DXH7KA] R clutch ECMV:Open .......................................................................................1293 Failure code [DXH7KB] R clutch ECMV:Short circuit ..............................................................................1294 Failure code [DXH7KY] R clutch ECMV:Hot short ..................................................................................1295 Failure code [DXH8KA] F clutch ECMV:Open .......................................................................................1297 Failure code [DXH8KB] F clutch ECMV:Short circuit ..............................................................................1298 Failure code [DXH8KY] F clutch ECMV:Hot short ..................................................................................1299 Failure code [DXHBKA] Right brake ECMV:Open ....................................................................................1301 Failure code [DXHBKB] Right brake ECMV:Short circuit ...........................................................................1303 Failure code [DXHBKY] Right brake ECMV:Hot short ...............................................................................1304 Failure code [DXHCKA] Left brake ECMV:Open .....................................................................................1306 Failure code [DXHCKB] Left brake ECMV:Short circuit ............................................................................1307 Failure code [DXHCKY] Left brake ECMV:Hot short ................................................................................1308 Failure code [DXHRKA] Blade lift up EPC:Open ...................................................................................1310 Failure code [DXHRKB] Blade lift up EPC:Short circuit ..........................................................................1311 Failure code [DXHRKY] Blade lift up EPC:Hot short ..............................................................................1312 Failure code [DXHSKA] Blade lift down EPC:Open .................................................................................1313 Failure code [DXHSKB] Blade lift down EPC:Short circuit ........................................................................1314 Failure code [DXHSKY] Blade lift down EPC:Hot short ............................................................................1315 Failure code [DXHTKA] Blade tilt right head EPC:Open ...........................................................................1316 Failure code [DXHTKB] Blade tilt right head EPC:Short circuit ..................................................................1318 Failure code [DXHTKY] Blade tilt right head EPC:Hot short ......................................................................1319 Failure code [DXHUKA] Blade tilt right bottom EPC:Open .........................................................................1320 Failure code [DXHUKB] Blade tilt right bottom EPC:Short circuit ................................................................1322 Failure code [DXHUKY] Blade tilt right bottom EPC:Hot short ....................................................................1323 Failure code [DXHWKA] Ripper lift up EPC:Open ..................................................................................1324 Failure code [DXHWKB] Ripper lift up EPC:Short circuit .........................................................................1325 Failure code [DXHWKY] Ripper lift up EPC:Hot short .............................................................................1326 Failure code [DXHXKA] Ripper lift down EPC:Open ................................................................................1327 Failure code [DXHXKB] Ripper lift down EPC:Short circuit .......................................................................1328 Failure code [DXHXKY] Ripper lift down EPC:Hot short ...........................................................................1329 Failure code [DXHYKA] Ripper tilt in EPC:Open ..................................................................................1330 Failure code [DXHYKB] Ripper tilt in EPC:Short circuit .........................................................................1331 Failure code [DXHYKY] Ripper tilt in EPC:Hot short .............................................................................1332 Failure code [DXHZKA] Ripper tilt back EPC:Open ................................................................................1333 Failure code [DXHZKB] Ripper tilt back EPC:Short circuit .......................................................................1334 Failure code [DXHZKY] Ripper tilt back EPC:Hot short ...........................................................................1335 Failure code [DXJ4KA] Weq lock Sol.:Open .......................................................................................1336 Failure code [DXJ4KB] Weq lock Sol.:Short circuit ..............................................................................1338 Failure code [DXJ8KA] Blade tilt left bottom EPC:Open ..........................................................................1339 Failure code [DXJ8KB] Blade tilt left bottom EPC:Short circuit .................................................................1341 Failure code [DXJ8KY] Blade tilt left bottom EPC:Hot ...........................................................................1342 Failure code [DXJ9KA] Blade tilt left head EPC:Open ............................................................................1343 Failure code [DXJ9KB] Blade tilt left head EPC:Short circuit ...................................................................1345 Failure code [DXJ9KY] Blade tilt left head EPC:Hot short .......................................................................1346 Failure code [DXJAKA] Quick drop solenoid:Open .................................................................................1347 Failure code [DXJAKB] Quick drop solenoid:Short circuit ........................................................................1348 Failure code [DXJAKY] Quick drop solenoid:Hot short ............................................................................1349 Failure code [DXJBKA] T/C Stator ECMV:Open .....................................................................................1350 Failure code [DXJBKB] T/C Stator ECMV:Short circuit ............................................................................1352 Failure code [DXJBKY] T/C Stator ECMV:Hot short ................................................................................1353 Troubleshooting of electrical system (E-mode) ......................................................................................1355 E-1 Engine does not start (Engine does not crank) ..............................................................................1355 E-2 Manual preheating system does not work .....................................................................................1361 E-3 Automatic preheating system does not work ..................................................................................1364 E-4 While preheating is working, preheating monitor does not light up ..........................................................1366 E-5 When starting switch is turned to ON position, machine monitor displays nothing ............................................1368 E-6 When starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow ....1371 E-7 Air cleaner clogging monitor lights up in yellow while engine is running ...................................................1373 E-8 Charge level monitor lights up in red while engine is running ..............................................................1374 E-9 Engine coolant temperature monitor lights up in red while engine is running ................................................1376 E-10 Engine oil pressure monitor lights up in red while engine is running ......................................................1377 E-11 Power train oil temperature monitor lights up in red while engine is running ..............................................1378 E-12 Hydraulic oil temperature monitor lights up in red while engine is running ................................................1379 E-13 Engine coolant temperature gauge does not indicate correct temparature ....................................................1380 E-14 Fuel level gauge does not indicate correct level ..........................................................................1381 E-15 Power train oil temperature gauge does not indicate correct temperature ...................................................1383 E-16 Hydraulic oil temperature gauge does not indicate correct temperature .....................................................1384 E-17 Operation mode does not change ............................................................................................1385 E-18 Gear shift mode does not change ...........................................................................................1386 E-19 Operating customize switch does not display customize screen ..............................................................1387 E-20 Modifying setting on customize screen does not change setting of machine ..................................................1388 E-21 Some areas of machine monitor screen are not displayed ....................................................................1389 E-22 Alarm buzzer does not sound or does not stop sounding .....................................................................1390 E-23 While starting switch is in OFF position, service meter is not displayed ..................................................1391 E-24 Service mode cannot be selected ...........................................................................................1392 E-25 Horn does not sound .......................................................................................................1393 E-26 Horn does not stop sounding ...............................................................................................1395 E-27 Backup alarm does not sound ...............................................................................................1396 E-28 Backup alarm does not stop sounding .......................................................................................1397 E-29 Headlamp does not light up ................................................................................................1398 E-30 Rear lamp and ripper point lamp do not light up ...........................................................................1401 E-31 No wiper operates continuously or intermittently ..........................................................................1404 E-32 Front wiper does not operate (failed continuous and intermittent operations) ..............................................1408 E-33 Rear wiper does not operate (failed continuous and intermittent operations) ...............................................1412 E-34 Left door wiper does not operate (failed continuous and intermittent operations) ..........................................1416 E-35 Right door wiper does not operate (failed continuous and intermittent operations) .........................................1420 E-36 Front washer does not operate .............................................................................................1424 E-37 Rear washer does not operate ..............................................................................................1426 E-38 Left door washer does not operate .........................................................................................1428 E-39 Right door washer does not operate ........................................................................................1430 E-40 Ripper pin puller does not work ...........................................................................................1432 E-41 Fan does not rotate in reverse ............................................................................................1434 E-42 Fuel feed pump does not operate or stop automatically .....................................................................1435 E-43 Gear cannot be shifted. ...................................................................................................1437 E-44 KOMTRAX system does not operate properly ..................................................................................1438 Troubleshooting for hydraulic and mechanical systems (H-mode) ......................................................................1440 Information described in troubleshooting table (H-mode) ........................................................................1440 System chart of hydraulic and mechanical systems ...............................................................................1441 Failure mode and cause table ...................................................................................................1445 H-1 Machine lacks power (insufficient drawbar pull) ............................................................................1451 H-2 Machine does not travel (at 2nd or 3rd gear speed) .........................................................................1454 H-3 Machine does not start at all gear speeds ..................................................................................1456 H-4 Machine travels only in one direction, either forward or in reverse ........................................................1459 H-5 Large time lag is in gear shifting or directional change ...................................................................1460 H-6 Machine cannot be steered (machine does not turn left or right) ............................................................1462 H-7 Steering speed or power is insufficient ....................................................................................1463 H-8 Brake does not work ........................................................................................................1464 H-9 Torque converter lockup clutch does not engage .............................................................................1465 H-10 Power train oil overheats .................................................................................................1466 H-11 Unusual noise is heard from around HSS pump or HSS motor ..................................................................1468 H-12 All work equipment operates slowly ........................................................................................1469 H-13 All work equipment do not operate .........................................................................................1470 H-14 Blade lift speed or power is low ..........................................................................................1471 H-15 Blade tilt speed or power is low ..........................................................................................1473 H-16 Ripper lift speed or power is low .........................................................................................1475 H-17 Ripper tilt speed or power is low .........................................................................................1477 H-18 Hydraulic drift of lifted blade is large ..................................................................................1479 H-19 Hydraulic drift of tilted blade is large ..................................................................................1480 H-20 Hydraulic drift of lifted ripper is large .................................................................................1481 H-21 Ripper pin puller cylinder does not operate ...............................................................................1482 H-22 Blade pitch cylinder does not operate .....................................................................................1483 H-23 Unusual noise is heard from around work equipment pump ....................................................................1484 H-24 Fan speed is abnormal (too high or low, or stationary) ....................................................................1485 H-25 Unusual noise is heard from around fan ....................................................................................1486 Troubleshooting of engine (S-mode) .................................................................................................1487 Information mentioned in troubleshooting table (S mode) ........................................................................1487 S-1 When starting switch is turned to START position, engine is not cranked ....................................................1488 S-2 The engine cranks but exhaust smoke does not come out ......................................................................1489 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) .....................1490 S-4 Startability is poor .......................................................................................................1491 S-5 Engine does not pick-up smoothly ...........................................................................................1494 S-6 Engine stops during operation ..............................................................................................1497 S-7 Engine runs rough or is unstable ...........................................................................................1499 S-8 Engine lacks power .........................................................................................................1500 S-9 Exhaust gas is black (KDPF gets clogged in a short time) ...................................................................1502 S-10 Engine oil consumption is excessive .......................................................................................1504 S-11 Engine oil becomes contaminated early .....................................................................................1505 S-12 Fuel consumption is excessive .............................................................................................1506 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ..........................................................1507 S-14 Oil pressure drops ........................................................................................................1508 S-15 Fuel mixes into engine oil ................................................................................................1509 S-16 Water mixes into engine oil (milky) .......................................................................................1510 S-17 Coolant temperature rises too high (overheating) ..........................................................................1511 S-18 Unusual noise is made .....................................................................................................1512 S-19 Vibration is excessive ....................................................................................................1513 S-20 Air cannot be bled from fuel circuit ......................................................................................1514 S-21 Active regeneration is executed frequently ................................................................................1515 S-22 Active regeneration takes a long time .....................................................................................1516 S-23 White smoke is exhausted during active regeneration .......................................................................1517 50 Disassembly and Assembly ............................................................................................................1519 Table of contents ..................................................................................................................1520 General information on disassembly and assembly ....................................................................................1522 How to read this manual ........................................................................................................1522 Coating materials list .........................................................................................................1524 Special tools list .............................................................................................................1528 Sketches of special tools ......................................................................................................1536 Engine and cooling system ..........................................................................................................1550 Removal and installation of fuel supply pump assembly ..........................................................................1550 Removal and installation of fuel injector assembly .............................................................................1555 Removal and installation of cylinder head assembly .............................................................................1567 Removal and installation of air cleaner assembly ...............................................................................1585 Removal and installation of KDPF assembly ......................................................................................1587 Disassembly and assembly of KDPF assembly ......................................................................................1590 Removal and installation of KCCV assembly ......................................................................................1600 Removal and installation of engine assembly ....................................................................................1601 Removal and installation of engine front seal ..................................................................................1607 Removal and installation of engine rear seal ...................................................................................1611 Removal and installation of radiator assembly ..................................................................................1616 Removal and installation of aftercooler assembly ...............................................................................1620 Removal and installation of hydraulic oil cooler assembly ......................................................................1622 Removal and installation of cooling fan drive assembly .........................................................................1624 Removal and installation of cooling in fan motor assembly ......................................................................1626 Removal and installation of engine hood assembly ...............................................................................1627 Removal and installation of fuel tank assembly .................................................................................1630 Power train ........................................................................................................................1632 Removal and installation of damper assembly ....................................................................................1632 Disassembly and assembly of damper assembly ....................................................................................1635 Removal and installation of power train unit assembly ..........................................................................1640 Disconnection and connection of power train unit assembly ......................................................................1644 Disassembly and assembly of PTO assembly .......................................................................................1648 Disassembly and assembly of torque converter assembly ..........................................................................1654 Disassembly and assembly of transmission assembly ..............................................................................1663 Disassembly and assembly of HSS assembly .......................................................................................1679 Removal and installation of HSS motor assembly .................................................................................1695 Removal and installation of final drive assembly ...............................................................................1696 Disassembly and assembly of final drive ........................................................................................1698 Undercarriage and frame ............................................................................................................1711 Removal and installation of track frame assembly ...............................................................................1711 Removal and installation of idler assembly .....................................................................................1715 Disassembly and assembly of idler assembly .....................................................................................1717 Removal and installation of recoil spring assembly .............................................................................1721 Disassembly and assembly of recoil spring assembly .............................................................................1722 Removal and installation of track roller assembly ..............................................................................1727 Disassembly and assembly of track roller assembly ..............................................................................1729 Removal and installation of 1st bogie assembly .................................................................................1732 Removal and installation of 2nd, 3rd, or 4th bogie assembly ....................................................................1737 Disassembly and assembly of bogie assembly .....................................................................................1742 Removal and installation of carrier roller assembly ............................................................................1744 Disassembly and assembly of carrier roller assembly ............................................................................1745 Removal and installation of pivot shaft assembly ...............................................................................1748 Separation and connection of track shoe assembly ...............................................................................1750 Overall disassembly and assembly of track shoe assembly ........................................................................1753 Field disassembly and assembly of one link .....................................................................................1765 Disassembly and assembly of master link ........................................................................................1769 Removal and installation of equalizer bar assembly .............................................................................1772 Disassembly and assembly of equalizer bar bushing ..............................................................................1774 Removal and installation of segment teeth ......................................................................................1776 Hydraulic system ...................................................................................................................1777 Removal and installation of hydraulic tank assembly ............................................................................1777 Removal and installation of control valve assembly .............................................................................1779 Removal and installation of work equipment pump and HSS pump assembly ..........................................................1781 Removal and installation of power train pump and steering lubrication pump assembly ............................................1783 Removal and installation of cooling fan pump assembly ..........................................................................1785 Removal and installation of scavenging pump assembly ...........................................................................1787 Disassembly and assembly of hydraulic cylinder assembly ........................................................................1788 Work equipment .....................................................................................................................1795 Removal and installation of blade assembly .....................................................................................1795 Disassembly and assembly of blade assembly .....................................................................................1797 Disassembly and assembly of multi-shank ripper assembly ........................................................................1801 Disassembly and assembly of giant ripper assembly ..............................................................................1805 Cab and its attachments ............................................................................................................1809 Removal and installation of operator's cab assembly ............................................................................1809 Removal and installation of operator's cab glass (adhesion glass) ..............................................................1814 Removal and installation of operator's seat ....................................................................................1820 Removal and installation of seat belt ..........................................................................................1821 Removal and installation of air conditioner unit assembly ......................................................................1822 Removal and installation of air conditioner compressor assembly ................................................................1826 Removal and installation of air conditioner condenser assembly .................................................................1828 Electrical system ..................................................................................................................1830 Removal and installation of machine monitor assembly ...........................................................................1830 Removal and installation of engine controller assembly .........................................................................1831 Removal and installation of power train controller assembly ....................................................................1833 Removal and installation of work equipment controller assembly .................................................................1834 Removal and installation of mass air flow and temperature sensor ...............................................................1835 Removal and installation of KOMTRAX terminal ...................................................................................1836 60 Maintenance standard ................................................................................................................1839 Table of contents ..................................................................................................................1840 Engine and cooling system ..........................................................................................................1841 Engine mount ...................................................................................................................1841 Damper .........................................................................................................................1842 Cooling system .................................................................................................................1844 Cooling fan pump ...............................................................................................................1847 Cooling fan motor ..............................................................................................................1851 Power train ........................................................................................................................1853 Power train mount ..............................................................................................................1853 Universal joint ................................................................................................................1855 Torque converter and PTO .......................................................................................................1856 Torque converter control valve .................................................................................................1862 Lockup clutch ECMV .............................................................................................................1863 Stator cluch ECMV ..............................................................................................................1864 Transmission ...................................................................................................................1865 Transmission ECMV ..............................................................................................................1870 Main relief valve and torque converter relief valve ............................................................................1871 Transmission lubrication relief valve ..........................................................................................1872 Bevel gear shaft, HSS, and brake ...............................................................................................1873 Brake control valve ............................................................................................................1879 Brake ECMV .....................................................................................................................1881 Brake solenoid valve ...........................................................................................................1882 Sudden stop prevention valve ...................................................................................................1883 Final drive ....................................................................................................................1884 Sprocket .......................................................................................................................1887 Full-scale drawing of sprocket tooth profile ...................................................................................1888 Undercarriage and frame ............................................................................................................1889 Main frame .....................................................................................................................1889 Suspension .....................................................................................................................1891 Track frame and idler cushion ..................................................................................................1893 Idler ..........................................................................................................................1895 Track roller ...................................................................................................................1897 Carrier roller .................................................................................................................1899 Track shoe .....................................................................................................................1900 Hydraulic system ...................................................................................................................1904 Hydraulic tank .................................................................................................................1904 Scavenging pump ................................................................................................................1905 Steering lubrication pump and power train pump .................................................................................1906 Work equipment and HSS pump ....................................................................................................1908 PC-EPC valve ...................................................................................................................1910 HSS motor ......................................................................................................................1911 Control valve ..................................................................................................................1914 Quick drop valve ...............................................................................................................1927 Self-pressure reducing valve ...................................................................................................1929 Work equipment .....................................................................................................................1931 Cylinder stay ..................................................................................................................1931 Blade ..........................................................................................................................1932 Cutting edge and end bit .......................................................................................................1934 Ripper .........................................................................................................................1935 Blade lift cylinder ............................................................................................................1939 Blade tilt cylinder ............................................................................................................1940 Ripper lift cylinder ...........................................................................................................1941 Ripper tilt cylinder ...........................................................................................................1942 Cab and its attachments ............................................................................................................1943 Cab mount ......................................................................................................................1943 80 Appendix ............................................................................................................................1945 Table of contents ..................................................................................................................1946 Air conditioner components .........................................................................................................1947 Precautions for refrigerant ....................................................................................................1947 Air conditioner component ......................................................................................................1948 Configuration and function of refrigeration cycle ..............................................................................1950 Outline of refrigeration cycle .................................................................................................1951 Air conditioner unit ...........................................................................................................1953 Air conditioner controller .....................................................................................................1959 Compressor .....................................................................................................................1960 Condenser ......................................................................................................................1961 Receiver drier .................................................................................................................1962 Sunlight sensor ................................................................................................................1963 Outer temperature sensor (outside air temperature sensor) ......................................................................1964 Procedure for testing and troubleshooting ......................................................................................1965 Circuit diagram and arrangement of connector pins ..............................................................................1967 System diagram .................................................................................................................1969 Parts and connectors layout ....................................................................................................1972 Testing air leakage (duct) .....................................................................................................1980 Testing with self-diagnosis function ...........................................................................................1983 Testing vent (mode) changeover .................................................................................................1986 Testing FRESH/RECIRC air changeover ............................................................................................1987 Testing sunlight sensor ........................................................................................................1988 Testing (dual) pressure switch for refrigerant .................................................................................1989 Testing relays .................................................................................................................1991 Troubleshooting chart 1 ........................................................................................................1992 Troubleshooting chart 2 ........................................................................................................1993 Information in troubleshooting table ...........................................................................................1995 Failure code list related to air conditioner ...................................................................................1996 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................1997 Failure code [879AKB] A/C Inner Sensor Short Circuit ...........................................................................1998 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................1999 Failure code [879BKB] A/C Outer Sensor Short Circuit ...........................................................................2001 Failure code [879CKA] Ventilating Sensor Open Circuit ..........................................................................2003 Failure code [879CKB] Ventilating Sensor Short Circuit .........................................................................2004 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....................................................................2005 Failure code [879EMC] Ventilation Damper Abnormality ...........................................................................2007 Failure code [879FMC] Air Mix Damper Abnormality ...............................................................................2008 Failure code [879GKX] Refrigerant Abnormality ..................................................................................2009 A-1 Troubleshooting for power supply system (Air conditioner does not operate) .................................................2010 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ..................................................2012 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .........................................2016 A-4 Troubleshooting for FRESH/RECIRC air changeover ............................................................................2018 Troubleshooting with gauge pressure ............................................................................................2020 Connection of service tool .....................................................................................................2023 Precautions for disconnecting and connecting refrigerant piping ................................................................2025 Handling of compressor oil .....................................................................................................2027 90 Drawings ............................................................................................................................2029 Table of contents ..................................................................................................................2030 Hydraulic circuit diagram ..........................................................................................................2031 Symbols in hydraulic circuit diagram ...........................................................................................2031 Power train hydraulic circuit diagram ..........................................................................................2035 Hydraulic circuit diagram ......................................................................................................2036 Electric circuit diagram ...........................................................................................................2038 Symbols in electric circuit diagram ............................................................................................2038 Electrical circuit diagram .....................................................................................................2042 Air conditioner electrical circuit diagram .....................................................................................2055
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⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
⦁ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
