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KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER: SEN04887-10
- SERIAL NUMBER:
D65EX- 80001 and up
DS5PX- 80001 and up
D65WX-80001 and up
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Description
KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SERVICE REPAIR MANUAL
KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SERVICE REPAIR MANUAL
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 explains the shop manuals list, table of contents, safety, and basic information-
01. Specification This section explains the specifications of the machine.
10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis- assembly and service.
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 instruments and measuring methods fortesting and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting This section explains how to find out failed parts and how to repair them- The troubleshooting is divided by failure modes. The “8 mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
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
80. Appendix This section explains the equipments which cannot be included in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting of the equipments.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SERVICE REPAIR MANUAL
COVER ......................................................................................................... 1 00 Index and foreword.......................................................................................... 0 100 Index.................................................................................................. 3 Composition of shop manual............................................................................. 4 Table of contents...................................................................................... 6 200 Foreword and general information....................................................................... 17 Safety notice.......................................................................................... 18 How to read the shop manual............................................................................ 23 Explanation of terms for maintenance standard.......................................................... 25 Handling of electric equipment and hydraulic component................................................. 27 Handling of connectors newly used for engines.......................................................... 36 How to read electric wire code......................................................................... 39 Precautions when carrying out operation................................................................ 42 Method of disassembling and connecting push-pull type coupler.......................................... 45 Standard tightening torque table....................................................................... 48 Conversion table....................................................................................... 52 01 General..................................................................................................... 0 100 Specification and technical data....................................................................... 59 Specification dimension drawing........................................................................ 60 Specifications......................................................................................... 66 Weight table........................................................................................... 78 Table of fuel, coolant and lubricants.................................................................. 82 10 Structure, function and maintenance standard................................................................ 0 100 Engine and cooling system.............................................................................. 85 Engine mount........................................................................................... 87 Cooling system......................................................................................... 88 Cooling fan pump....................................................................................... 90 Cooling fan motor...................................................................................... 104 Coolant preheater (subextremely cold weather spec.).................................................... 110 201 Power train, Part 1.................................................................................... 115 Power train............................................................................................ 116 HSS system............................................................................................. 118 Overall view of power train unit....................................................................... 120 Power train hydraulic piping diagram................................................................... 124 Transmission, steering and brake control............................................................... 126 Damper................................................................................................. 128 Universal joint........................................................................................ 130 Torque converter and PTO............................................................................... 131 Transmission........................................................................................... 138 Transmission control valve............................................................................. 156 ECMV................................................................................................... 160 Main relief and torque converter relief valve.......................................................... 168 Main relief and torque converter relief valve (subextremely cold weather spec.)........................ 170 Transmission lubrication relief valve.................................................................. 172 202 Power train, Part 2.................................................................................... 175 Bevel gear shaft, HSS and brake........................................................................ 176 Brake valve............................................................................................ 198 Final drive............................................................................................ 204 Final drive (Planetary gear installed inside of sprocket type)......................................... 210 300 Undercarriage and frame................................................................................ 217 Main frame............................................................................................. 218 Suspension............................................................................................. 220 Track frame and idler cushion.......................................................................... 230 Idler.................................................................................................. 234 Track roller........................................................................................... 236 Carrier roller......................................................................................... 242 Sprocket............................................................................................... 244 Track shoe............................................................................................. 248 401 Hydraulic system, Part 1............................................................................... 255 Work equipment hydraulic system layout drawing......................................................... 256 Work equipment control................................................................................. 260 Hydraulic tank and filter.............................................................................. 262 Scavenging pump........................................................................................ 264 Power train and steering lubrication pump.............................................................. 265 HSS pump............................................................................................... 266 HSS motor.............................................................................................. 285 402 Hydraulic system, Part 2............................................................................... 295 Control valve.......................................................................................... 296 CLSS................................................................................................... 305 Function and operation of each valve................................................................... 308 403 Hydraulic system, Part 3............................................................................... 333 PPC valve (blade lift, blade tilt)..................................................................... 334 PPC valve (ripper)..................................................................................... 340 Electric lever (steering).............................................................................. 344 Quick drop valve....................................................................................... 348 Work equipment lock solenoid valve..................................................................... 350 Pitch selector solenoid valve.......................................................................... 354 Hydraulic oil cooler bypass valve...................................................................... 355 Accumulator............................................................................................ 356 500 Work equipment......................................................................................... 359 Blade.................................................................................................. 360 Cutting edge and end bit............................................................................... 368 Ripper (Multi shank)................................................................................... 370 Ripper (Single shank).................................................................................. 371 Hydraulic cylinder..................................................................................... 372 Piston valve........................................................................................... 376 600 Cab and its attachme................................................................................... 379 Cab mount.............................................................................................. 380 Cab.................................................................................................... 381 Subextremely cold spec. cab (subextremely cold weather spec.).......................................... 382 600 Cab and its attachmentsFRP canopy mountFRP canopy mount............................................ 383 FRP canopy............................................................................................. 384 700 Electrical system...................................................................................... 387 Monitor system......................................................................................... 388 Engine control system.................................................................................. 404 Cooling system control system.......................................................................... 407 Electronic steering control system..................................................................... 409 KOMTRAX system......................................................................................... 412 KOMTRAX terminal (for GPRS)............................................................................ 414 System components...................................................................................... 415 Sensor................................................................................................. 423 20 Standard value table........................................................................................ 0 100 Standard service value table........................................................................... 431 Standard service value table for engine................................................................ 432 Standard service value table for chassis............................................................... 434 30 Testing and adjusting....................................................................................... 0 101 Testing and adjusting, Part 1.......................................................................... 447 Tools for testing, adjusting, and troubleshooting...................................................... 448 Testing engine speed................................................................................... 451 Testing intake air pressure (boost pressure)........................................................... 453 Testing exhaust temperature............................................................................ 455 Testing exhaust gas color.............................................................................. 457 Adjusting valve clearance.............................................................................. 458 Testing compression pressure........................................................................... 460 Testing blow-by pressure............................................................................... 464 Testing engine oil pressure............................................................................ 465 Handling of fuel system devices........................................................................ 466 Releasing residual pressure from fuel system........................................................... 466 Testing fuel pressure.................................................................................. 467 Testing fuel return and leak amount.................................................................... 472 Bleeding air from fuel circuit......................................................................... 474 Testing fuel circuit for leakage....................................................................... 475 Handling of reduced cylinder mode operation............................................................ 476 Handling of no injection cranking operation............................................................ 476 Testing and adjusting air conditioner compressor belt tension.......................................... 477 Replacing alternator belt.............................................................................. 478 Adjusting fuel control dial and decelerator pedal...................................................... 479 Handling controller high-voltage circuit............................................................... 480 102 Testing and adjusting, Part 2.......................................................................... 483 Testing power train oil pressure....................................................................... 485 Adjusting transmission output shaft speed sensor (replacement procedure)............................... 490 Simple test procedure for brake performance............................................................ 491 Adjusting brake pedal.................................................................................. 492 Adjusting parking brake lever.......................................................................... 494 Emergency escape method when power train has trouble................................................... 496 Adjusting clearance of idler........................................................................... 499 Inspecting wear of sprocket............................................................................ 500 Inspecting wear of sprocket............................................................................ 501 Testing and adjusting track shoe tension............................................................... 502 Testing and adjusting work equipment and HSS oil pressure.............................................. 503 Testing control circuit basic pressure................................................................. 506 Testing PPC valve output pressure...................................................................... 507 Adjusting work equipment PPC valve play................................................................ 509 Testing internal leakage of work equipment cylinder.................................................... 513 Bleeding air from work equipment cylinder.............................................................. 514 Releasing residual pressure from work equipment cylinder............................................... 514 Checking parts which caused hydraulic drift of blade or ripper......................................... 515 Adjusting work equipment lock lever.................................................................... 516 Adjusting work equipment lock lever (FRP canopy specification)......................................... 517 Testing fan speed...................................................................................... 519 Testing fan circuit oil pressure....................................................................... 520 Bleeding air from fan pump............................................................................. 521 Bleeding air from HSS pump............................................................................. 522 Adjusting straight tiltdozer........................................................................... 523 Adjusting play of blade center ball1................................................................... 525 Adjusting operator’s cab............................................................................... 526 103 Testing and adjusting, Part 3.......................................................................... 531 Special functions of machine monitor (EMMS)............................................................ 532 104 Testing and adjusting, Part 4.......................................................................... 589 Handling of voltage circuit of engine controller....................................................... 590 Adjustment method when controller has been replaced.................................................... 591 Preparation work for troubleshooting of electrical..................................................... 593 Inspection procedure of diode.......................................................................... 597 Pm-Clinic service...................................................................................... 598 40 Troubleshooting............................................................................................. 0 100 Failure code table and fuse locations.................................................................. 613 Failure codes table.................................................................................... 614 Fuse locations......................................................................................... 619 200 General information on troubleshooting................................................................. 623 Points to remember when troubleshooting................................................................ 624 How to proceed troubleshooting......................................................................... 625 Checks before troubleshooting.......................................................................... 626 Classification and procedures for troubleshooting...................................................... 628 Symptom supposed to be failure and troubleshooting No.................................................. 632 Information contained in troubleshooting table......................................................... 634 Troubleshooting method for disconnecting wiring harness of pressure sensor system...................... 636 Connector list and stereogram.......................................................................... 638 Connection table for connector pin numbers............................................................. 652 T- branch box and T- branch adapter table.............................................................. 688 301 Troubleshooting by failure code (Display of code), Part 1.............................................. 693 Failure code [1500L0] Transmission clutch: Abnormal.................................................... 695 Failure code [15SAL1] Forward clutch: Fill high........................................................ 696 Failure code [15SALH] Forward clutch: Fill low......................................................... 698 Failure code [15SBL1] Reverse clutch: Fill high........................................................ 700 Failure code [15SBLH] Reverse clutch: Fill low......................................................... 702 Failure code [15SEL1] Speed 1st clutch: Fill high...................................................... 704 Failure code [15SELH] Speed 1st clutch: Fill low....................................................... 706 Failure code [15SFL1] Speed 2nd clutch: Fill high...................................................... 708 Failure code [15SFLH] Speed 2nd clutch: Fill low....................................................... 710 Failure code [15SGL1] Speed 3rd clutch: Fill high...................................................... 712 Failure code [15SGLH] Speed 3rd clutch: Fill low....................................................... 714 Failure code [15SJL1] L/U: Fill high................................................................... 716 Failure code [15SJLH] L/U: Fill low.................................................................... 718 Failure code [AB00MA] Battery Charge Abnormal.......................................................... 720 Failure code [B@BAZG] Eng Oil Press Low................................................................ 722 Failure code [B@BCNS] Eng Water Overheat............................................................... 722 Failure code [B@CENS] T/C Oil Overheat................................................................. 723 Failure code [B@HANS] Hyd Oil Overheat................................................................. 723 302 Troubleshooting by failure code (Display of code), Part 2.............................................. 725 Failure code [CA111] ECM Critical Internal Failure..................................................... 727 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.................................................. 727 Failure code [CA122] Chg Air Press Sensor High Error................................................... 728 Failure code [CA123] Chg Air Press Sensor Low Error.................................................... 730 Failure code [CA131] Throttle Sensor High Error........................................................ 732 Failure code [CA132] Throttle Sensor Low Error......................................................... 734 Failure code [CA144] Coolant Temp Sens High Error...................................................... 736 Failure code [CA145] Coolant Temp Sens Low Error....................................................... 738 Failure code [CA153] Chg Air Temp Sensor High Error.................................................... 740 Failure code [CA154] Chg Air Temp Sensor Low Error..................................................... 742 Failure code [CA155] Chg Air Temp High Speed Derate.................................................... 744 Failure code [CA187] Sens Supply 2 Volt Low Error...................................................... 746 Failure code [CA221] Ambient Press Sens High Error..................................................... 748 Failure code [CA222] Ambient Press Sens Low Error...................................................... 750 Failure code [CA227] Sens Supply 2 Volt High Error..................................................... 752 Failure code [CA234] Eng Overspeed..................................................................... 752 Failure code [CA238] Ne Speed Sens Supply Volt Error................................................... 753 Failure code [CA271] IMV/PCV1 Short Error.............................................................. 754 Failure code [CA272] IMV/PCV1 Open Error............................................................... 756 Failure code [CA281] Abnormal supply pump pressure balance............................................. 758 Failure code [CA322] Inj #1(L#1) Open/Short Error...................................................... 760 Failure code [CA323] Inj #5(L#5) Open/Short Error...................................................... 762 Failure code [CA324] Inj #3(L#3) Open/Short Error...................................................... 764 Failure code [CA325] Inj #6(L#6) Open/Short Error...................................................... 766 Failure code [CA331] Inj #2(L#2) Open/Short Error...................................................... 768 Failure code [CA332] Inj #4(L#4) Open/Short Error...................................................... 770 303 Troubleshooting by failure code (Display of code), Part 3.............................................. 773 Failure code [CA342] Calibration Code Incompatibility.................................................. 775 Failure code [CA351] Injectors Drive Circuit Error..................................................... 775 Failure code [CA352] Sens Supply 1 Volt Low Error...................................................... 776 Failure code [CA386] Sens Supply 1 Volt High Error..................................................... 778 Failure code [CA428] Water in Fuel Sensor High Error................................................... 780 Failure code [CA429] Water in Fuel Sensor Low Error.................................................... 782 Failure code [CA435] Eng Oil Press Sw Error............................................................ 784 Failure code [CA441] Battery Voltage Low Error......................................................... 786 Failure code [CA442] Battery Voltage High Error........................................................ 788 Failure code [CA449] Rail Press Very High Error........................................................ 790 Failure code [CA451] Rail Press Sensor High Error...................................................... 792 Failure code [CA452] Rail Press Sensor Low Error....................................................... 794 Failure code [CA488] Chg Air Temp High Torque Derate................................................... 796 Failure code [CA553] Rail Press High Error............................................................. 797 Failure code [CA559] Rail Press Low Error.............................................................. 798 Failure code [CA689] Eng Ne Speed Sensor Error......................................................... 800 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................... 804 Failure code [CA757] All Continuous Data Lost Error.................................................... 805 Failure code [CA778] Eng Bkup Speed Sensor Error....................................................... 806 Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 809 Failure code [CA2185] Throt Sens Sup Volt High Error................................................... 810 Failure code [CA2186] Throt Sens Sup Volt Low Error.................................................... 812 Failure code [CA2249] Rail Press Very Low Error........................................................ 814 Failure code [CA2265] Fuel Feed Pump Open Error........................................................ 816 Failure code [CA2266] Fuel Feed Pump Short Error....................................................... 818 Failure code [CA2311] IMV Solenoid Error............................................................... 819 Failure code [CA2555] Grid Htr Relay Volt High Error................................................... 820 Failure code [CA2556] Grid Htr Relay Volt Low Error.................................................... 822 304 Troubleshooting by failure code (Display of code), Part 4.............................................. 825 Failure code [D110KB] Battery relay drive: Short circuit............................................... 828 Failure code [D130KA] Neutral relay: Disconnection..................................................... 830 Failure code [D130KB] Neutral relay: Short circuit..................................................... 832 Failure code [D161KA] Back-up alarm relay: Disconnection............................................... 834 Failure code [D161KB] Back-up alarm relay: Short circuit............................................... 836 Failure code [D862KA] GPS Antenna Open Circuit......................................................... 838 Failure code [DAFRKR] CAN Disconnection................................................................ 839 Failure code [DAFRMC] CAN Discon (Monitor Detected).................................................... 840 Failure code [DB2RKR] CAN Disconnection................................................................ 843 Failure code [DBE0KT] PT controller: Abnormality in controller......................................... 848 Failure code [DBE1KK] Battery direct Source voltage reduction.......................................... 850 Failure code [DBE2KK] Solenoid Source voltage reduction................................................ 852 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction........................................ 854 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction........................................... 856 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction........................................ 858 Failure code [DBE9KQ] PT controller: Type select signal................................................ 860 Failure code [DD12KA] Shift up Sw: Disconnection....................................................... 862 Failure code [DD12KB] Shift up Sw: Short circuit....................................................... 864 Failure code [DD13KA] Shift down Sw: Disconnection..................................................... 866 Failure code [DD13KB] Shift down Sw: Short circuit..................................................... 868 Failure code [DD14KA] Parking lever Sw: Disconnection.................................................. 870 Failure code [DD14KB] Parking lever Sw: Short circuit.................................................. 872 305 Troubleshooting by failure code (Display of code), Part 5.............................................. 875 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection................................................ 878 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit................................................ 880 Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection.................................................. 882 Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit.................................................. 884 Failure code [DDNLKA] Weq lock Sw: Disconnection....................................................... 886 Failure code [DDNLKB] Weq lock Sw: Short circuit....................................................... 888 Failure code [DGS1KX] Hyd oil temp sensor: Abnormal.................................................... 890 Failure code [DGT1KA] T/C oil temp sensor: Disconnection............................................... 892 Failure code [DGT1KX] T/C oil temp sensor: Short circuit............................................... 894 Failure code [DH21KA] Weq pressure sensor: Disconnection............................................... 896 Failure code [DH21KB] Weq pressure sensor: Short circuit............................................... 898 Failure code [DHT5KA] T/C pressure sensor: Disconnection............................................... 900 Failure code [DHT5KB] T/C pressure sensor: Short circuit............................................... 902 Failure code [DK10KA] Fuel control Dial: Disconnection................................................. 904 Failure code [DK10KB] Fuel control Dial: Short circuit................................................. 906 Failure code [DK30KA] ST lever 1: Disconnection........................................................ 908 Failure code [DK30KB] ST lever 1: Short circuit........................................................ 910 Failure code [DK30KX] ST lever: Out of normal range.................................................... 912 Failure code [DK30KZ] ST lever: Disconnection or short circuit......................................... 912 Failure code [DK30L8] ST lever: Signal mismatch........................................................ 913 Failure code [DK31KA] ST lever 2: Disconnection........................................................ 914 Failure code [DK31KB] ST lever 2: Short circuit........................................................ 916 Failure code [DK40KA] Brake potentiometer: Disconnection............................................... 918 Failure code [DK40KB] Brake potentiometer: Short circuit............................................... 920 Failure code [DK55KX] FR lever: Out of normal range.................................................... 922 Failure code [DK55KZ] FR lever: Disconnection or short circuit......................................... 922 Failure code [DK55L8] FR lever: Signal mismatch........................................................ 923 Failure code [DK56KA] FR lever 1: Disconnection........................................................ 924 Failure code [DK56KB] FR lever 1: Short circuit........................................................ 926 Failure code [DK57KA] FR lever 2: Disconnection........................................................ 928 Failure code [DK57KB] FR lever 2: Short circuit........................................................ 930 306 Troubleshooting by failure code (Display of code), Part 6.............................................. 933 Failure code [DKH1KA] Pitch angle sensor: Disconnection................................................ 936 Failure code [DKH1KB] Pitch angle sensor: Short circuit................................................ 938 Failure code [DLT3KA] T/M out-speed sensor: Disconnection.............................................. 940 Failure code [DLT3KB] T/M out-speed sensor: Abnormal................................................... 941 Failure code [DW5AKA] Pitch selector Sol.: Disconnection............................................... 942 Failure code [DW5AKB] Pitch selector Sol.: Short circuit............................................... 943 Failure code [DW5AKY] Pitch selector Sol.: Short circuit............................................... 944 Failure code [DW7BKA] Fan rev EPC: Disconnection....................................................... 946 Failure code [DW7BKB] Fan rev EPC: Short circuit....................................................... 947 Failure code [DWN1KA] Hss EPC1: Disconnection.......................................................... 948 Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................... 949 Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................... 950 Failure code [DWN2KA] Hss EPC2: Disconnection.......................................................... 951 Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................... 952 Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................... 953 Failure code [DWN5KA] Fan pump solenoid: Disconnection................................................. 954 Failure code [DWN5KB] Fan pump solenoid: Short circuit................................................. 955 Failure code [DWN5KY] Fan control solenoid: Short circuit.............................................. 956 Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................... 958 Failure code [DXA0KB] TVC Sol.: Short circuit.......................................................... 959 Failure code [DXA0KY] TVC Sol.: Short circuit.......................................................... 960 Failure code [DXH1KA] Lock-up ECMV: Disconnection...................................................... 961 Failure code [DXH1KB] Lock-up ECMV: Short circuit...................................................... 962 Failure code [DXH1KY] Lock-up ECMV: Short circuit...................................................... 964 Failure code [DXH4KA] 1st clutch ECMV: Disconnection................................................... 966 Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................... 967 Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................... 968 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................... 969 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................... 970 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit................................................... 971 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection................................................... 972 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................... 973 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................... 974 Failure code [DXH7KA] R clutch ECMV: Disconnection..................................................... 975 Failure code [DXH7KB] R clutch ECMV: Short circuit..................................................... 976 Failure code [DXH7KY] R clutch ECMV: Short circuit..................................................... 978 Failure code [DXH8KA] F clutch ECMV: Disconnection..................................................... 980 Failure code [DXH8KB] F clutch ECMV: Short circuit..................................................... 981 Failure code [DXH8KY] F clutch ECMV: Short circuit..................................................... 982 Failure code [DXJ4KA] Weq lock Sol.: Disconnection..................................................... 984 Failure code [DXJ4KB] Weq lock Sol.: Short circuit..................................................... 985 400 Troubleshooting of electrical system (E-mode).......................................................... 987 Before troubleshooting of electrical system............................................................ 989 Information in troubleshooting table................................................................... 991 E-1 Engine does not start (starting motor does not turn)............................................... 993 E-2 Preheater does not operate......................................................................... 996 E-3 When starting switch is turned ON, machine monitor displays nothing................................1002 E-4 When starting switch is turned ON (before starting engine), basic check item lights up.............1004 E-5 Precaution item lights up while engine is running..................................................1006 E-6 Emergency stop item lights up while engine is running..............................................1008 E-7 Engine coolant temperature gauge does not indicate normally........................................1010 E-8 Fuel gauge does not indicate properly..............................................................1012 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally.........................1015 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally..............................1016 E-11 Contents of display by machine monitor are different from applicable machine......................1017 E-12 Machine monitor does not display some items.......................................................1017 E-13 Function switch does not work.....................................................................1017 E-14 Operation mode does not change....................................................................1018 E-15 Gearshift mode does not change....................................................................1018 E-16 Customize function does not operate normally......................................................1019 E-17 Customize memory function does not operate normally...............................................1019 E-18 Alarm buzzer does not sound or does not stop......................................................1020 E-19 When starting switch is turned OFF, service meter is not displayed................................1020 E-20 Machine monitor cannot be set in service mode.....................................................1020 E-21 Horn does not sound or does not stop..............................................................1021 E-22 Back-up alarm does not sound or does not stop.....................................................1022 E-23 Head lamp or rear lamp does not light up..........................................................1024 E-24 Windshield wiper does not operate.................................................................1028 E-25 Window washer does not operate....................................................................1042 E-26 KOMTRAX system does not operate correctly.........................................................1047 500 Troubleshooting of hydraulic and mechanical system (H-mode)............................................1049 Failure mode and cause table...........................................................................1050 Contents of troubleshooting table......................................................................1052 H-1 There is no travel power (no drawbar pull).........................................................1053 H-2 Machine does not move (at 2nd or 3rd speed)........................................................1054 H-3 Machine does not move at any gear speed............................................................1055 H-4 Machine travels only in one direction, forward or in reverse.......................................1056 H-5 When gear is shifted or travel direction is changed, large time lag is made........................1057 H-6 Machine cannot be steered (Machine does not turn leftward or rightward)............................1058 H-7 Steering speed or power is low.....................................................................1058 H- 8 Brake does not work...............................................................................1059 H-9 Overheat of power train oil........................................................................1060 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor.....................1061 H-11 All work equipment speeds are slow................................................................1061 H-12 Work equipment does not move......................................................................1062 H-13 Blade lift speed is slow or lacks power...........................................................1062 H-14 Blade tilt speed is slow or lacks power...........................................................1063 H-15 Ripper lift speed is slow or lacks power..........................................................1063 H-16 Excessive hydraulic drift of blade lift...........................................................1064 H-17 Excessive hydraulic drift of blade tilt...........................................................1064 H-18 Excessive hydraulic drift of ripper lift..........................................................1065 600 Troubleshooting of engine (S-mode).....................................................................1067 Method of using troubleshooting charts.................................................................1069 S-1 Starting performance is poor.......................................................................1072 S-2 Engine does not start..............................................................................1073 S-3 Engine does not pick up smoothly...................................................................1076 S-4 Engine stops during operations.....................................................................1077 S-5 Engine does not rotate smoothly....................................................................1078 S-6 Engine lacks output (or lacks power)...............................................................1079 S-7 Exhaust smoke is black (incomplete combustion).....................................................1080 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................1081 S-9 Oil becomes contaminated quickly...................................................................1082 S-10 Fuel consumption is excessive.....................................................................1083 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)............................1084 S-12 Oil pressure drops................................................................................1085 S-13 Oil level rises (water, fuel in oil)..............................................................1086 S-14 Coolant temperature becomes too high (overheating)................................................1087 S-15 Abnormal noise is made............................................................................1088 S-16 Vibration is excessive............................................................................1089 50 Disassembly and assembly.................................................................................... 0 100 General information on disassembly and assembly........................................................1091 How to read this manual................................................................................1092 Coating materials list.................................................................................1094 Special tool list......................................................................................1097 Sketches of special tools..............................................................................1107 200 Engine and cooling system..............................................................................1123 Removal and installation of fuel supply pump assembly..................................................1124 Removal and installation of fuel injector assembly.....................................................1129 Removal and installation of cylinder head assembly.....................................................1139 Removal and installation of radiator assembly..........................................................1154 Removal and installation of aftercooler assembly.......................................................1157 Removal and installation of hydraulic oil cooler assembly..............................................1159 Removal and installation of power train oil cooler assembly............................................1161 Removal and installation of cooling fan drive assembly.................................................1164 Removal and installation of cooling fan motor assembly.................................................1166 Removal and installation of main body of coolant preheater (subextremely cold weather spec)............1168 Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)..............1172 Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)..........1174 Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.).......1178 Removal and installation of damper assembly............................................................1187 Removal and installation of engine front oil seal......................................................1190 Removal and installation of engine rear oil seal.......................................................1194 Removal and installation of engine hood assembly.......................................................1202 Removal and installation of fuel tank assembly.........................................................1204 300 Power train............................................................................................1207 Removal and installation of power train unit assembly..................................................1208 Separation and connection of power train unit assembly.................................................1212 Disassembly and assembly of PTO assembly...............................................................1217 Disassembly and assembly of torque converter assembly..................................................1222 Disassembly and assembly of transmission assembly......................................................1233 Disassembly and assembly of HSS assembly...............................................................1260 Removal and installation of final drive assembly.......................................................1280 Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)....1282 Disassembly and assembly of final drive assembly.......................................................1284 Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)....1292 400 Undercarriage and frame................................................................................1307 Removal and installation of track frame assembly.......................................................1308 Removal and installation of idler assembly.............................................................1310 Disassembly and assembly of idler assembly.............................................................1312 Disassembly and assembly of idler assembly.............................................................1314 Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment).........1318 Removal and installation of recoil spring assembly.....................................................1323 Disassembly and assembly of recoil spring assembly.....................................................1324 Removal and installation of track roller assembly......................................................1328 Disassembly and assembly of track roller assembly......................................................1329 Removal and installation of carrier roller assembly....................................................1333 Disassembly and assembly of carrier roller assembly....................................................1334 Expansion and installation of track shoe assembly (Conventional type track shoe).......................1337 Expansion and installation of track shoe assembly (PLUS type track shoe)...............................1340 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe).............1341 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).....................1355 Field disassembly and assembly of one link (Conventional type track shoe)..............................1367 Field disassembly and assembly of one link (PLUS type track shoe)......................................1374 Removal and installation of pivot shaft assembly.......................................................1379 Removal and installation of equalizer bar assembly.....................................................1380 Disassembly and assembly of equalizer bar side bushing.................................................1382 500 Hydraulic system.......................................................................................1385 Removal and installation of hydraulic tank assembly....................................................1386 Removal and installation of control valve assembly.....................................................1389 Disassembly and assembly of control valve assembly.....................................................1392 Disassembly and assembly of blade lift and tilt PPC valve assembly.....................................1394 Disassembly and assembly of ripper PPC valve assembly..................................................1395 Removal and installation of HSS and cooling fan pump assembly..........................................1396 Removal and installation of power train and lubrication pump assembly..................................1398 Removal and installation of scavenging pump assembly...................................................1400 Removal and installation of HSS motor assembly.........................................................1401 Disassembly and assembly of hydraulic cylinder assembly................................................1404 600 Work equipment.........................................................................................1411 Removal and installation of blade assembly (ST-TPP dozer)..............................................1412 Removal and installation of blade assembly (PAT dozer).................................................1415 Removal and installation of ripper assembly............................................................1417 700 Cab and its attachments................................................................................1421 Removal and installation of ROPS cab assembly..........................................................1422 Removal and installation of operator’s cab glass (Stuck glass).........................................1429 Removal and installation of floor frame assembly (FRP canopy specification)............................1430 Removal and installation of operator’s cab glass (Stuck glass).........................................1434 Removal and installation of air conditioner unit assembly..............................................1440 Removal and installation of air conditioner compressor assembly........................................1444 800 Electrical system......................................................................................1447 Removal and installation of monitor panel assembly.....................................................1448 Removal and installation of engine controller assembly.................................................1450 Removal and installation of power train controller assembly............................................1452 Removal and installation of KOMTRAX terminal assembly..................................................1454 80 Appendix.................................................................................................... 0 100 Air conditioner........................................................................................1457 Structure and function.................................................................................1460 Air conditioner component..........................................................................1460 Configuration and function of refrigerating cycle..................................................1462 Outline of refrigerating cycle.....................................................................1463 Air conditioner unit...............................................................................1466 Control plate......................................................................................1470 Compressor.........................................................................................1471 Condenser..........................................................................................1472 Receiver drier.....................................................................................1473 Testing, adjusting and troubleshooting.................................................................1474 Caution about refrigerant..........................................................................1474 Troubleshooting procedure..........................................................................1475 Block diagram......................................................................................1476 Circuit diagram and arrangement of connector pins..................................................1478 Detail of air conditioner unit.....................................................................1480 Parts and connectors arrangement...................................................................1482 Testing air leakage (duct).........................................................................1488 Testing with self-diagnosis function...............................................................1490 Testing temperature control........................................................................1493 Testing vent (mode) changeover.....................................................................1495 Testing Recirc/Fresh changeover....................................................................1498 Testing inner sensor...............................................................................1499 Testing evaporator temperature sensor..............................................................1500 Testing sunlight sensor............................................................................1503 Testing (dual) pressure switch for refrigerant.....................................................1504 Testing relays and diodes..........................................................................1506 Troubleshooting chart 1............................................................................1508 Troubleshooting chart 2............................................................................1509 Troubleshooting for electrical system (E mode).....................................................1512 E-1 Power supply system (Air conditioner does not operate).....................................1513 E-2 Compressor and refrigerant system (Air is not cooled)......................................1516 E-3 Blower motor system (No air comes out or air flow is abnormal).............................1519 E-4 Temperature cannot be controlled...........................................................1522 E-5 Vent (mode) cannot be changed over.........................................................1524 E-6 Recirc/Fresh air cannot be changed over....................................................1526 Troubleshooting with gauge pressure................................................................1528 Connection of service tool.........................................................................1531 Precautions for connecting air conditioner piping..................................................1532 Handling of compressor oil.........................................................................1533 1. Control of compressor oil (Denso: ND-OIL8: For R134a).......................................1533 2. Adding of compressor oil....................................................................1533 3. Compressor replacement......................................................................1534 4. Applying compressor oil for O-ring..........................................................1534 90 Diagrams and drawings....................................................................................... 0 100 Hydraulic diagrams and drawings........................................................................1537 Power train hydraulic circuit diagram..................................................................1539 Work equipment hydraulic circuit diagram...............................................................1541 200 Electrical diagrams and drawings.......................................................................1547 Electrical circuit diagram.............................................................................1549 Electrical circuit diagram (Sand terrain specification)................................................1568 Electrical circuit diagram (FRP canopy specification)..................................................1571
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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