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KOMATSU D65EX -15E0 D65PX -15E0 D65WX-15E0 BULLDOZER SERVICE REPAIR MANUAL(SN 69001 AND UP) – PDF DOWNLOAD
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- KOMATSU D65EX -15E0 D65PX -15E0 D65WX-15E0 BULLDOZER SERVICE REPAIR MANUAL
- SERIAL NUMBERS
D65EX- 69001 and up
D65PX- 69001 and up
D65WX-69001 and up - PUBLICATION NUMBER:SEN00046-09
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Description
KOMATSU D65EX -15E0 D65PX -15E0 D65WX-15E0 BULLDOZER SERVICE REPAIR MANUAL(SN 69001 AND UP)
KOMATSU D65EX -15E0 D65PX -15E0 D65WX-15E0 BULLDOZER SERVICE REPAIR MANUAL(SN 69001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D65EX -15E0 D65PX -15E0 D65WX-15E0 BULLDOZER SERVICE REPAIR MANUAL(SN 69001 AND UP)
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” 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
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams
TABLE OF CONTENTS:
KOMATSU D65EX -15E0 D65PX -15E0 D65WX-15E0 BULLDOZER SERVICE REPAIR MANUAL(SN 69001 AND UP)
COVER............................................................................................................................................ 1 00 Index and foreword............................................................................................................................ 0 Index........................................................................................................................................ 2 Composition of shop manual............................................................................................................... 3 Table of contents........................................................................................................................ 5 Foreword and general information............................................................................................................. 16 Safety notice............................................................................................................................ 17 How to read the shop manual.............................................................................................................. 22 Explanation of terms for maintenance standard............................................................................................ 24 Handling of electric equipment and hydraulic component................................................................................... 26 Handling of connectors newly used for engines............................................................................................ 35 How to read electric wire code........................................................................................................... 38 Precautions when carrying out operation.................................................................................................. 41 Method of disassembling and connecting push-pull type coupler............................................................................ 44 Standard tightening torque table......................................................................................................... 47 Conversion table......................................................................................................................... 51 01 Specification................................................................................................................................. 0 Specification and technical data............................................................................................................. 58 Specification and technical data......................................................................................................... 59 Specification dimensions............................................................................................................. 59 Specifications....................................................................................................................... 60 Weight table......................................................................................................................... 65 Table of fuel, coolant and lubricants................................................................................................ 67 10 Structure, function and maintenance standard.................................................................................................. 0 Engine and cooling system.................................................................................................................... 70 Engine and cooling system................................................................................................................ 71 Cooling system....................................................................................................................... 71 Cooling fan pump..................................................................................................................... 73 Cooling fan motor.................................................................................................................... 81 Power train, Part 1.......................................................................................................................... 88 Power train, Part 1...................................................................................................................... 89 Power train.......................................................................................................................... 89 HSS system........................................................................................................................... 91 General view of power train unit..................................................................................................... 93 Power train hydraulic piping drawing................................................................................................. 95 Transmission, steering and brake control............................................................................................. 97 Damper and universal joint........................................................................................................... 99 Torque converter and PTO............................................................................................................. 102 Transmission......................................................................................................................... 107 Transmission clutch ECMV............................................................................................................. 123 Main relief valve and torque converter relief valve.................................................................................. 129 Lubrication relief valve............................................................................................................. 131 Power train, Part 2.......................................................................................................................... 134 Power train, Part 2...................................................................................................................... 135 Bevel gear shaft, HSS and brake...................................................................................................... 135 Brake valve.......................................................................................................................... 157 Final drive.......................................................................................................................... 163 Undercarriage and frame...................................................................................................................... 170 Undercarriage and frame.................................................................................................................. 171 Main frame........................................................................................................................... 171 Suspension........................................................................................................................... 173 Track frame and idler cushion........................................................................................................ 179 Idler................................................................................................................................ 183 Track roller......................................................................................................................... 185 Carrier roller....................................................................................................................... 189 Sprocket............................................................................................................................. 191 Track shoe........................................................................................................................... 195 Hydraulic system, Part 1..................................................................................................................... 202 Hydraulic system, Part 1................................................................................................................. 203 Work equipment hydraulic piping diagram.............................................................................................. 203 Work equipment control............................................................................................................... 205 Hydraulic tank and filter............................................................................................................ 207 Scavenging pump...................................................................................................................... 209 Power train and steering lubrication pump............................................................................................ 210 HSS pump............................................................................................................................. 211 HSS motor............................................................................................................................ 229 Hydraulic system, Part 2..................................................................................................................... 237 Hydraulic system, Part 2................................................................................................................. 238 Control valve........................................................................................................................ 238 Self pressure reducing valve......................................................................................................... 270 Hydraulic system, Part 3..................................................................................................................... 278 Hydraulic system, Part 3................................................................................................................. 279 PPC valve (blade lift, blade tilt)................................................................................................... 279 PPC valve (ripper)................................................................................................................... 285 Electric lever (steering)............................................................................................................ 289 Quick drop valve..................................................................................................................... 292 PPC lock valve....................................................................................................................... 294 Accumulator.......................................................................................................................... 295 Work equipment............................................................................................................................... 297 Work equipment........................................................................................................................... 298 Blade................................................................................................................................ 298 Cutting edge and end bit............................................................................................................. 302 Ripper............................................................................................................................... 303 Hydraulic cylinder................................................................................................................... 304 Piston valve......................................................................................................................... 307 Cab and its attachments...................................................................................................................... 309 Cab and its attachments.................................................................................................................. 310 Cab mount............................................................................................................................ 310 Cab.................................................................................................................................. 311 Air conditioner...................................................................................................................... 313 Electrical system............................................................................................................................ 315 Electrical system........................................................................................................................ 316 Monitor system....................................................................................................................... 316 Monitor panel........................................................................................................................ 318 Engine control....................................................................................................................... 327 Engine control system................................................................................................................ 328 Cooling system control system........................................................................................................ 330 System components.................................................................................................................... 332 Palm command control system.......................................................................................................... 340 KOMTRAX system....................................................................................................................... 342 Sensor............................................................................................................................... 344 20 Standard value table.......................................................................................................................... 0 Standard service value table................................................................................................................. 349 Standard service value table............................................................................................................. 350 Standard service value table for engine.............................................................................................. 350 Standard service value table for chassis............................................................................................. 352 30 Testing and adjusting......................................................................................................................... 0 Testing and adjusting, Part 1................................................................................................................ 365 Tools for testing, adjusting, and troubleshooting........................................................................................ 367 Measuring engine speed................................................................................................................... 370 Measuring intake air pressure (boost pressure)........................................................................................... 372 Measuring exhaust temperature............................................................................................................ 374 Measuring exhaust gas color.............................................................................................................. 376 Adjusting valve clearance................................................................................................................ 377 Measuring compression pressure........................................................................................................... 380 Measuring blow-by pressure............................................................................................................... 384 Measuring engine oil pressure............................................................................................................ 385 Handling of fuel system devices.......................................................................................................... 386 Releasing residual pressure from fuel system............................................................................................. 386 Testing fuel pressure.................................................................................................................... 387 Testing fuel return and leak amount...................................................................................................... 392 Bleeding air from fuel circuit........................................................................................................... 394 Testing fuel circuit for leakage......................................................................................................... 395 Handling of reduced cylinder mode operation.............................................................................................. 396 Testing and adjusting air conditioner compressor belt tension............................................................................ 397 Adjusting fuel control dial and decelerator pedal........................................................................................ 398 Measuring power train oil pressure....................................................................................................... 400 Adjusting transmission speed sensor (replacement procedure).............................................................................. 404 Simple method to test brake performance.................................................................................................. 405 Adjusting brake pedal.................................................................................................................... 406 Adjusting parking brake lever............................................................................................................ 408 Emergency escape method when power train has trouble..................................................................................... 409 Adjusting clearance of idler............................................................................................................. 412 Inspecting wear of sprocket.............................................................................................................. 413 Testing and adjusting track shoe tension................................................................................................. 413 Testing and adjusting work equipment and HSS oil pressure................................................................................ 414 Testing control circuit basic pressure................................................................................................... 417 Measuring PPC valve output pressure...................................................................................................... 418 Adjusting work equipment PPC valve play.................................................................................................. 420 Measuring internal leakage of work equipment cylinder.................................................................................... 422 Bleeding air from work equipment cylinder................................................................................................ 422 Releasing residual pressure in work equipment cylinder................................................................................... 423 Checking parts which caused hydraulic drift of blade or ripper........................................................................... 424 Adjusting work equipment lock lever...................................................................................................... 425 Measuring fan motor speed................................................................................................................ 426 Measuring fan pump circuit pressure...................................................................................................... 427 Bleeding air from fan pump............................................................................................................... 428 Adjusting straight tiltdozer............................................................................................................. 429 Testing and adjusting operator cab....................................................................................................... 431 Testing and adjusting, Part 2................................................................................................................ 437 Testing and adjusting, Part 2............................................................................................................ 438 Special functions of monitor panel (EMMS)............................................................................................ 438 Testing and adjusting, Part 3................................................................................................................ 481 Testing and adjusting, Part 3............................................................................................................ 482 Adjustment method when controller has been replaced.................................................................................. 482 Preparation work for troubleshooting for electric system............................................................................. 484 Inspection procedure of diode........................................................................................................ 489 Pm-Clinic service.................................................................................................................... 490 How to start operation of KOMTRAX terminal........................................................................................... 500 Lamp display of KOMTRAX terminal..................................................................................................... 504 Handling of voltage circuit of engine controller..................................................................................... 482 40 Troubleshooting............................................................................................................................... 0 General information on troubleshooting....................................................................................................... 509 Points to remember when troubleshooting.................................................................................................. 510 How to proceed troubleshooting........................................................................................................... 511 Checks before troubleshooting............................................................................................................ 512 Classification and procedures of troubleshooting......................................................................................... 513 How to distinguish wire code............................................................................................................. 516 Connection table for connector pin numbers............................................................................................... 520 T- branch box and T- branch adapter table................................................................................................ 556 Troubleshooting by failure code (Display of code), Part 1.................................................................................... 561 Failure code table....................................................................................................................... 563 Before troubleshooting by failure codes.................................................................................................. 570 Contents of troubleshooting table........................................................................................................ 572 Failure code [1500L0] Transmission clutch: Dual engagement............................................................................... 574 Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF...................................................... 576 Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON...................................................... 578 Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF...................................................... 580 Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON...................................................... 582 Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF.......................................................... 584 Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON.......................................................... 585 Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF.......................................................... 586 Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON.......................................................... 588 Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF.......................................................... 590 Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON.......................................................... 592 Failure code [AB00MA] Alternator: Malfunction............................................................................................ 594 Failure code [B@BAZG] Engine oil: Oil pressure too low................................................................................... 594 Failure code [B@BCNS] Radiator coolant: Overheat......................................................................................... 595 Failure code [B@CENS] Power train oil: Overheat.......................................................................................... 595 Failure code [B@HANS] Hydraulic oil: Overheat............................................................................................ 596 Failure code [CA111] Engine controller: Abnormality in controller........................................................................ 597 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal............................................. 597 Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected.................................................. 598 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected.................................................... 600 Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected................................................ 602 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.................................................. 604 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected.............................................. 606 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected................................................ 608 Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected............................................... 610 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected................................................. 612 Failure code [CA155] Charge temperature too high and engine speed derated: Exceeded upper control limit of temperature................... 614 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected..................................................... 616 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected............................................. 618 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected............................................... 620 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected................................................... 622 Failure code [CA234] Engine over speed: Excessively high speed........................................................................... 624 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected......................................... 625 Failure code [CA271] IMV/PCV1 short circuit: Short circuit............................................................................... 626 Failure code [CA272] IMV/PCV1 disconnection: Disconnection............................................................................... 628 Failure code [CA281] Abnormal supply pump pressure balance: Abnormal pressure feed of fuel............................................... 630 Troubleshooting by failure code (Display of code), Part 2.................................................................................... 633 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit.................................. 636 Failure code [CA323] Injector No. 5 system disconnection or short circuit: disconnection, short circuit.................................. 638 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit.................................. 640 Failure code [CA325] Injector No. 6 system disconnection or short circuit: disconnection, short circuit.................................. 642 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit.................................. 644 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit.................................. 646 Failure code [CA342] Engine controller data matching error: matching error............................................................... 648 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected..................................................... 650 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected................................................... 652 Failure code [CA428] Water detection sensor too high: Excessively high voltage detected.................................................. 654 Failure code [CA429] Water detection sensor too low: Excessively low voltage detected.................................................... 656 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit........................................................ 658 Failure code [CA441] Power source voltage too low: Excessively low voltage detected...................................................... 660 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit......... 662 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred....................................... 664 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected............................................. 668 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected............................................... 670 Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature......................... 672 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected............................................... 673 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected.......................................... 674 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal.................................................................... 676 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase............................................................. 678 Failure code [CA757] Loss of all engine controller data: Loss of all data................................................................ 680 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal............................................................. 682 Failure code [CA1633] Abnormal KOMNET: Abnormal communication............................................................................ 684 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected.................................. 686 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected.................................... 687 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected......................................... 688 Failure code [CA2265] Electric lift pump disconnection: Disconnection.................................................................... 690 Failure code [CA2266] Electric lift pump short circuit: Short circuit.................................................................... 692 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance......................................................................... 694 Failure code [CA2555] Air intake heater relay disconnection: Disconnection............................................................... 696 Failure code [CA2556] Air intake heater relay short circuit: Short circuit............................................................... 698 Troubleshooting by failure code (Display of code), Part 3.................................................................................... 701 Troubleshooting by failure code (Display of code), Part 3................................................................................ 704 Failure code [D110KA] Battery relay: Short circuit................................................................................... 704 Failure code [D110KB] Battery relay: Disconnection................................................................................... 706 Failure code [D130KA] Neutral safety relay: Disconnection............................................................................ 708 Failure code [D130KB] Neutral safety relay: Short circuit............................................................................ 710 Failure code [D161KA] Back-up alarm relay: Disconnection............................................................................. 712 Failure code [D161KB] Back-up alarm relay: Short circuit............................................................................. 714 Failure code [DAFRKR] Monitor panel CAN communication: Defective communication....................................................... 716 Failure code [DAQ0KT] [DB30KT] Steering and transmission controller: Abnormality in controller....................................... 718 Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input........ 720 Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input........ 722 Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input..... 724 Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input.... 726 Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal............ 728 Failure code [DB2RKR] Steering and transmission controller CAN communication: Defective communication................................ 730 Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller....................................... 732 Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input........ 732 Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input....... 732 Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input..... 732 Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input.... 732 Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection: Inconsistency in model select signal............ 732 Failure code [DD12KA] Shift up switch: Disconnection................................................................................. 734 Failure code [DD12KB] Shift up switch: Short circuit................................................................................. 736 Failure code [DD13KA] Shift down switch: Disconnection............................................................................... 738 Failure code [DD13KB] Shift down switch: Short circuit............................................................................... 740 Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection............................................................. 742 Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit............................................................. 744 Failure code [DDN7KA] Pitch control switch: Disconnection............................................................................ 746 Failure code [DDN7KB] Pitch control switch: Short circuit............................................................................ 748 Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection............................................................. 750 Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit............................................................. 750 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range.......................................... 752 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection.............................................................. 754 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range........................................ 755 Failure code [DK10KA] Fuel dial: Disconnection....................................................................................... 756 Failure code [DK10KB] Fuel dial: Short circuit....................................................................................... 758 Failure code [DK30KA] Steering potentiometer (1): Disconnection...................................................................... 760 Failure code [DK30KB] Steering potentiometer (1): Short circuit...................................................................... 762 Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range.................................................... 764 Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure)........................................ 765 Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal............................................................. 765 Failure code [DK31KA] Steering potentiometer (2): Disconnection...................................................................... 766 Failure code [DK31KB] Steering potentiometer (2): Short circuit...................................................................... 768 Failure code [DK40KA] Brake potentiometer: Disconnection............................................................................. 770 Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................. 771 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range............................................. 772 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit (Double failure)................................. 773 Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal...................................................... 774 Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit............................................................... 776 Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection............................................................... 778 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................................................... 780 Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit............................................................... 782 Troubleshooting by failure code (Display of code), Part 4.................................................................................... 785 Troubleshooting by failure code (Display of code), Part 4................................................................................ 787 Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit..................................................................... 787 Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection..................................................................... 788 Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range............................................ 789 Failure code [DLT3KA] Transmission output speed sensor: Disconnection................................................................ 790 Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................................................ 791 Failure code [DV00KB] Alarm buzzer: Short circuit.................................................................................... 792 Failure code [DW5AKA] Pitch control solenoid: Disconnection.......................................................................... 793 Failure code [DW5AKB] Pitch control solenoid: Short circuit.......................................................................... 794 Failure code [DW5AKY] Pitch control solenoid: Short circuit to power source line..................................................... 795 Failure code [DW7BKA] Fan reverse solenoid: Disconnection............................................................................ 796 Failure code [DW7BKB] Fan reverse solenoid: Short circuit............................................................................ 797 Failure code [DWN1KA] HSS EPC solenoid right: Disconnection.......................................................................... 798 Failure code [DWN1KB] HSS EPC solenoid right: Short circuit.......................................................................... 799 Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line..................................................... 800 Failure code [DWN2KA] HSS EPC solenoid left: Disconnection........................................................................... 801 Failure code [DWN2KB] HSS EPC solenoid left: Short circuit........................................................................... 802 Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line...................................................... 803 Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection........................................................................... 804 Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit........................................................................... 805 Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line...................................................... 806 Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection........................................................................... 807 Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit........................................................................... 808 Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line...................................................... 809 Failure code [DXH4KA] 1st clutch ECMV: Disconnection................................................................................. 810 Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 811 Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line............................................................ 812 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................................................. 813 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................................................. 814 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line............................................................ 815 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection................................................................................. 816 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................. 817 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line............................................................ 818 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection............................................................................. 819 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit............................................................................. 820 Failure code [DXH7KY] reverse clutch ECMV: Short circuit to power source line........................................................ 821 Failure code [DXH8KA] Forward clutch ECMV: Disconnection............................................................................. 822 Failure code [DXH8KB] Forward clutch ECMV: Short circuit............................................................................. 823 Failure code [DXH8KY] forward clutch ECMV: Short circuit to power source line........................................................ 824 Troubleshooting of electrical system (E-mode)................................................................................................ 826 Troubleshooting of electrical system (E-mode)............................................................................................ 828 Before troubleshooting of electrical system.......................................................................................... 828 Contents of troubleshooting table.................................................................................................... 830 E-1 The engine does not start (the starting motor does not turn)..................................................................... 831 E-2 The preheater does not operate................................................................................................... 835 E-3 The monitor panel does not light up at all when the starting switch is turned ON................................................. 839 E-4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.......................... 840 E-5 While the engine is running, the battery charge level caution lamp flashes....................................................... 841 E-6 While the engine is running, the emergency warning item flashes.................................................................. 843 E-7 While the preheater is operating, the preheating pilot lamp does not light up.................................................... 847 E-8 The coolant temperature gauge does not indicate correctly........................................................................ 849 E-9 The power train oil temperature gauge does not indicate correctly................................................................ 851 E-10 Hydraulic oil temperature gauge does not indicate properly...................................................................... 854 E-11 Fuel gauge does not indicate properly........................................................................................... 857 E-12 Gear speed and engine speed are not indicated properly.......................................................................... 858 E-13 The preset mode service meter does not indicate normally........................................................................ 858 E-14 The warning lamp does not flash or does not go out.............................................................................. 858 E-15 The alarm buzzer does not sound or does not stop................................................................................ 859 E-16 Auto shift down is not possible or is not released.............................................................................. 861 E-17 The buzzer cancel switch does not work.......................................................................................... 863 E-18 The information switch does not work............................................................................................ 865 E-19 The fan cleaning does not operate or cannot be reset............................................................................ 867 E-20 The preset mode does not operate or cannot be reset............................................................................. 869 E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode.................................... 871 E-22 The back-up alarm does not sound................................................................................................ 873 E-23 The head lamp and rear lamp do not light up..................................................................................... 875 E-24 The horn does not sound or does not stop........................................................................................ 878 E-25 Malfunction of wipers........................................................................................................... 879 E-26 Washer does not spray water..................................................................................................... 895 E-27 The air conditioner does not operate............................................................................................ 901 E-28 KOMTRAX system does not operate normally........................................................................................ 905 Troubleshooting of hydraulic and mechanical system (H-mode).................................................................................. 908 Troubleshooting of hydraulic and mechanical system (H-mode).............................................................................. 910 Contents of troubleshooting table.................................................................................................... 910 H-1 There is no travel power (no drawbar pull)....................................................................................... 911 H-2 Machine does not move (at 2nd or 3rd speed)...................................................................................... 912 H-3 Machine does not move at any gear speed.......................................................................................... 913 H-4 Machine travels only in one direction, forward or in reverse..................................................................... 914 H-5 When gear is shifted or travel direction is changed, large time lag is made...................................................... 915 H-6 Machine cannot be steered (Machine does not turn leftward or rightward).......................................................... 916 H-7 Steering speed or power is low................................................................................................... 916 H- 8 Brake does not work............................................................................................................. 917 H-9 Overheat of power train oil...................................................................................................... 918 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................................................... 919 H-11 All work equipment speeds are slow.............................................................................................. 919 H-12 Work equipment does not move.................................................................................................... 920 H-13 Blade lift speed is slow or lacks power......................................................................................... 920 H-14 Blade tilt speed is slow or lacks power......................................................................................... 921 H-15 Ripper lift speed is slow or lacks power........................................................................................ 921 H-16 Excessive hydraulic drift of blade lift......................................................................................... 922 H-17 Excessive hydraulic drift of blade tilt......................................................................................... 922 H-18 Excessive hydraulic drift of ripper lift........................................................................................ 923 Troubleshooting of engine (S-mode)........................................................................................................... 925 Troubleshooting of engine (S-mode)....................................................................................................... 927 Method of using troubleshooting charts............................................................................................... 927 S-1 Starting performance is poor..................................................................................................... 930 S-2 Engine does not start............................................................................................................ 931 S-3 Engine does not pick up smoothly................................................................................................. 934 S-4 Engine stops during operations................................................................................................... 935 S-5 Engine does not rotate smoothly.................................................................................................. 936 S-6 Engine lacks output (or lacks power)............................................................................................. 937 S-7 Exhaust smoke is black (imcomplete combustion)................................................................................... 938 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................... 939 S-9 Oil becomes contaminated quickly................................................................................................. 940 S-10 Fuel consumption is excessive................................................................................................... 941 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down).......................................................... 942 S-12 Oil pressure drops.............................................................................................................. 943 S-13 Oil level rises (water, fuel in oil)............................................................................................ 944 S-14 Coolant temperature becomes too high (overheating).............................................................................. 945 S-15 Abnormal noise is made.......................................................................................................... 946 S-16 Vibration is excessive.......................................................................................................... 947 50 Disassembly and assembly...................................................................................................................... 0 General information on disassembly and assembly.............................................................................................. 949 How to read this manual.................................................................................................................. 950 Coating materials list................................................................................................................... 952 Special tool list........................................................................................................................ 955 Sketches of special tools................................................................................................................ 961 Engine and cooling system, Part 1............................................................................................................ 971 Engine and cooling system, Part 1........................................................................................................ 972 Removal and installation of fuel supply pump assembly................................................................................ 972 Removal and installation of cylinder head assembly................................................................................... 976 Removal and installation of fuel injector assembly................................................................................... 991 Removal and installation of engine front oil seal.................................................................................... 993 Removal and installation of engine rear oil seal..................................................................................... 996 Engine and cooling system, Part 2............................................................................................................1003 Engine and cooling system, Part 2........................................................................................................1004 Removal and installation of engine assembly..........................................................................................1004 Removal and installation of radiator assembly........................................................................................1011 Removal and installation of air aftercooler assembly.................................................................................1015 Removal and installation of fan drive assembly.......................................................................................1016 Removal and installation of fan motor assembly.......................................................................................1017 Removal and installation of fuel tank assembly.......................................................................................1018 Removal and installation of damper assembly..........................................................................................1020 Removal and installation of engine hood assembly.....................................................................................1021 Power train, Part 1..........................................................................................................................1023 Power train, Part 1......................................................................................................................1024 Removal and installation of power train unit assembly................................................................................1024 Disconnection and connection of power train unit assembly............................................................................1027 Disassembly and assembly of PTO assembly.............................................................................................1031 Disassembly and assembly of torque converter assembly................................................................................1037 Disassembly and assembly of TORQFLOW transmission assembly...........................................................................1042 Power train, Part 2..........................................................................................................................1061 Power train, Part 2......................................................................................................................1062 Disassembly and assembly of HSS assembly.............................................................................................1062 Removal and installation of final drive assembly.....................................................................................1080 Disassembly and assembly of final drive assembly.....................................................................................1082 Undercarriage and frame, Part 1..............................................................................................................1090 Undercarriage and frame, Part 1..........................................................................................................1091 Removal and installation of track frame assembly.....................................................................................1091 Removal and installation of idler assembly...........................................................................................1093 Disassembly and assembly of idler assembly...........................................................................................1094 Removal and installation of recoil spring assembly...................................................................................1098 Disassembly and assembly of recoil spring assembly...................................................................................1099 Removal and installation of track roller assembly....................................................................................1103 Disassembly and assembly of track roller assembly....................................................................................1104 Removal and installation of carrier roller assembly..................................................................................1108 Disassembly and assembly of carrier roller assembly..................................................................................1109 Undercarriage and frame, Part 2..............................................................................................................1113 Expansion and installation of track shoe assembly (Conventional type track shoe).........................................................1114 Expansion and installation of track shoe assembly (PLUS type track shoe).................................................................1117 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)...............................................1118 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).......................................................1131 Field disassembly and assembly of one link (Conventional type track shoe)................................................................1144 Field disassembly and assembly of one link (PLUS type track shoe)........................................................................1151 Removal and installation of pivot shaft assembly.........................................................................................1156 Removal and installation of equalizer bar assembly.......................................................................................1157 Disassembly and assembly of equalizer bar side bushing...................................................................................1159 Hydraulic system.............................................................................................................................1161 Hydraulic system.........................................................................................................................1162 Removal and installation of control valve assembly...................................................................................1162 Disassembly and assembly of control valve assembly...................................................................................1164 Removal and installation of HSS pump assembly........................................................................................1165 Removal and installation of power train and lubricating oil pump assembly............................................................1166 Removal and installation of cooling fan pump assembly................................................................................1167 Removal and installation of scavenging pump assembly.................................................................................1169 Removal and installation of HSS motor assembly.......................................................................................1170 Disassembly and assembly of hydraulic cylinder assembly..............................................................................1171 Work equipment...............................................................................................................................1178 Work equipment...........................................................................................................................1179 Removal and installation of blade assembly...........................................................................................1179 Cab and its attachments......................................................................................................................1182 Cab and its attachments..................................................................................................................1183 Removal and installation of ROPS guard...............................................................................................1183 Removal and installation of operator’s cab assembly..................................................................................1184 Removal and installation of operator’s cab glass (Stuck glass).......................................................................1190 Removal and installation of floor frame assembly.....................................................................................1198 Electrical system............................................................................................................................1206 Electrical system........................................................................................................................1207 Removal and installation of engine controller........................................................................................1207 Removal and installation of steering and transmission controller assembly............................................................1209 Removal and installation of KOMTRAX terminal.........................................................................................1210 90 Diagrams and drawings......................................................................................................................... 0 Hydraulic diagrams and drawings..............................................................................................................1212 Hydraulic diagrams and drawings..........................................................................................................1213 Power train hydraulic circuit diagram................................................................................................1213 Hydraulic circuit diagram............................................................................................................1214 Electrical diagrams and drawings.............................................................................................................1217 Electrical circuit diagram...............................................................................................................1219 Connector list and stereogram............................................................................................................1227
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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