Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Service Manual PDF

Description

Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06645-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06645-04 – PDF DOWNLOAD 

Language : English
Pages : 2950
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06645-04 – PDF DOWNLOAD 

SERIAL NUMBERS
D65EX- 90997 and up
D65PX- 90997 and up
D65WX-90997 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06645-04 – PDF DOWNLOAD 

SERIAL NUMBERS
D65EX- 90997 and up
D65PX- 90997 and up
D65WX-90997 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
PRECAUTIONS FOR DEF 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 43
THE OTHER PRECAUTIONS 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: D65EX-18 103
SPECIFICATION DRAWING: D65PX-18 105
SPECIFICATION DRAWING: D65WX-18 107
SPECIFICATIONS 109
SPECIFICATIONS: D65EX-18 109
SPECIFICATIONS: D65PX-18 117
SPECIFICATIONS: D65WX-18 123
WEIGHT TABLE 130
WEIGHT TABLE: D65EX-18 130
WEIGHT TABLE: D65PX-18 134
WEIGHT TABLE: D65WX-18 137
TABLE OF FUEL, COOLANT, AND LUBRICANTS 140
10 STRUCTURE AND FUNCTION 143
CONTENTS 144
ABBREVIATION LIST 147
UREA SCR SYSTEM 153
LAYOUT DRAWING OF UREA SCR SYSTEM 153
UREA SCR SYSTEM DIAGRAM 155
FUNCTION OF UREA SCR SYSTEM 156
FUNCTION OF AdBlue/DEF SYSTEM 156
INDUCEMENT STRATEGY 158
COMPONENT PARTS OF UREA SCR SYSTEM 172
AdBlue/DEF MIXING TUBE 172
SCR ASSEMBLY 172
AdBlue/DEF TANK 175
AdBlue/DEF PUMP 177
AdBlue/DEF INJECTOR 178
AdBlue/DEF HOSE 179
AdBlue/DEF TANK HEATING VALVE 180
BOOT-UP SYSTEM 181
LAYOUT DRAWING OF BOOT-UP SYSTEM 181
SYSTEM OPERATING LAMP SYSTEM 183
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 183
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 183
BATTERY DISCONNECT SWITCH 185
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 185
FUNCTION OF BATTERY DISCONNECT SWITCH 185
ENGINE SYSTEM 187
LAYOUT DRAWING OF ENGINE SYSTEM 187
ENGINE CONTROL SYSTEM 189
LAYOUT OF ENGINE CONTROL SYSTEM 189
ENGINE CONTROL SYSTEM DIAGRAM 190
FUNCTION OF ENGINE CONTROL SYSTEM 192
AUTOMATIC IDLE STOP SYSTEM 194
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 194
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 194
COMPONENT PARTS OF ENGINE SYSTEM 197
DAMPER 197
VGT 199
EGR SYSTEM 203
EGR VALVE 205
EGR COOLER 207
KCCV SYSTEM 209
KCCV VENTILATOR 211
KDPF 213
COOLING SYSTEM 217
LAYOUT DRAWING OF COOLING SYSTEM 217
SPECIFICATIONS OF COOLING SYSTEM 218
COOLING FAN CONTROL SYSTEM 219
COOLING FAN CONTROL SYSTEM DIAGRAM 219
FUNCTION OF COOLING FAN CONTROL SYSTEM 220
COMPONENT PARTS OF COOLING SYSTEM 222
COOLING FAN PUMP 222
COOLING FAN MOTOR 231
HYDRAULIC OIL COOLER BYPASS VALVE 237
CONTROL SYSTEM 239
LAYOUT DRAWING OF CONTROL SYSTEM 239
MACHINE MONITOR SYSTEM 240
MACHINE MONITOR SYSTEM DIAGRAM 240
FUNCTION OF MACHINE MONITOR SYSTEM 240
KOMTRAX SYSTEM 241
KOMTRAX SYSTEM DIAGRAM 241
FUNCTION OF KOMTRAX SYSTEM 241
COMPONENT PARTS OF CONTROL SYSTEM 242
MACHINE MONITOR 242
KOMTRAX TERMINAL 258
POWER TRAIN CONTROLLER 260
ENGINE CONTROLLER 264
HYDRAULIC SYSTEM 271
LAYOUT DRAWING OF HYDRAULIC SYSTEM 271
CLSS 272
STRUCTURE OF CLSS 272
FUNCTION OF CLSS 273
COMPONENT PARTS OF HYDRAULIC SYSTEM 275
HYDRAULIC TANK 275
WORK EQUIPMENT AND HSS PUMP 276
LS VALVE 282
PC VALVE 287
PC-EPC VALVE 292
CONTROL VALVE 295
POWER TRAIN SYSTEM 326
LAYOUT DRAWING OF POWER TRAIN SYSTEM 326
OPERATION OF POWER TRAIN SYSTEM 328
TRANSMISSION, STEERING, AND BRAKE CONTROL 329
LAYOUT DRAWING OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM 329
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL 330
PALM COMMAND CONTROL SYSTEM 331
PALM COMMAND CONTROL SYSTEM DIAGRAM 331
HSS SYSTEM 335
HSS SYSTEM DIAGRAM 335
FUNCTION OF HSS SYSTEM 336
CENTRALIZED PRESSURE PICKUP PORT 338
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT 338
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT 338
COMPONENT PARTS OF POWER TRAIN SYSTEM 339
UNIVERSAL JOINT 339
POWER TRAIN MOUNT 340
TORQUE CONVERTER AND PTO 340
LOCKUP CLUTCH ECMV 346
TRANSMISSION 349
TRANSMISSION CONTROL VALVE 361
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 363
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 368
TRANSMISSION LUBRICATION RELIEF VALVE 370
BEVEL GEAR SHAFT, HSS, AND BRAKE 371
BRAKE VALVE 390
FINAL DRIVE 394
SCAVENGING PUMP 398
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 399
HSS MOTOR 400
ELECTRIC STEERING CONTROL LEVER 406
WORK EQUIPMENT SYSTEM 409
WORK EQUIPMENT CONTROL 409
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 409
FUNCTION OF WORK EQUIPMENT CONTROL 410
LAYOUT OF TILT DOZER, POWER TILT PITCH DOZER AND ANGLE DOZER SERIES 412
LAYOUT OF POWER ANGLE POWER TILT DOZER SERIES 413
LAYOUT OF FIXED MULTI-SHANK RIPPER 414
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 415
SELF-PRESSURE REDUCING VALVE 415
WORK EQUIPMENT LOCK SOLENOID VALVE 421
BLADE PPC VALVE 426
RIPPER PPC VALVE 432
BLADE PITCH SELECTOR SOLENOID VALVE 435
PILOT CIRCUIT ACCUMULATOR 436
ANGLE CONTROL EPC VALVE 437
QUICK DROP VALVE 440
PISTON VALVE 442
UNDERCARRIAGE AND FRAME 444
MAIN FRAME 444
STRUCTURE OF MAIN FRAME 444
SUSPENSION 446
STRUCTURE OF SUSPENSION 446
SPECIFICATIONS OF SUSPENSION 447
FUNCTION OF SUSPENSION 448
TRACK FRAME AND IDLER CUSHION 449
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 449
FUNCTION OF TRACK FRAME AND IDLER CUSHION 451
WORK EQUIPMENT 452
STRUCTURE OF FRONT WORK EQUIPMENT (FOR TILT DOZER AND POWER TILT PITCH DOZER SERIES) 452
STRUCTURE OF FRONT WORK EQUIPMENT (FOR POWER ANGLE POWER TILT DOZER SERIES) 453
STRUCTURE OF FRONT WORK EQUIPMENT (ANGLE DOZER SERIES) 454
STRUCTURE OF FIXED MULTI-SHANK RIPPER 455
CAB AND ITS ATTACHMENTS 456
ROPS CAB 456
STRUCTURE OF ROPS CAB 456
FUNCTION OF ROPS CAB 457
CAB MOUNT 458
STRUCTURE OF CAB MOUNT 458
FUNCTION OF CAB MOUNT 458
20 STANDARD VALUE TABLE 459
CONTENTS 460
ABBREVIATION LIST 461
STANDARD VALUE TABLE FOR ENGINE 467
STANDARD VALUE TABLE FOR ENGINE: D65EX-18 467
STANDARD VALUE TABLE FOR ENGINE: D65PX-18 472
STANDARD VALUE TABLE FOR ENGINE: D65WX-18 477
STANDARD VALUE TABLE FOR MACHINE 482
STANDARD VALUE TABLE FOR MACHINE: D65EX-18 482
STANDARD VALUE TABLE FOR MACHINE: D65PX-18 498
STANDARD VALUE TABLE FOR MACHINE: D65WX-18 514
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 529
STANDARD VALUE TABLE FOR ELECTRICAL 532
STANDARD VALUE TABLE FOR ELECTRICITY 532
30 TESTING AND ADJUSTING 541
CONTENTS 542
ABBREVIATION LIST 545
RELATED INFORMATION ON TESTING AND ADJUSTING 551
TOOLS FOR TESTING AND ADJUSTING 551
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 557
ENGINE AND COOLING SYSTEM 558
TEST ENGINE SPEED 558
METHOD FOR TESTING ENGINE SPEED 558
TEST BOOST PRESSURE 562
METHOD FOR TESTING BOOST PRESSURE 562
TEST EXHAUST GAS TEMPERATURE 564
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 564
TEST EXHAUST GAS COLOR 566
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 566
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 566
TEST AND ADJUST VALVE CLEARANCE 568
METHOD FOR TESTING VALVE CLEARANCE 568
METHOD FOR ADJUSTING VALVE CLEARANCE 569
TEST COMPRESSION PRESSURE 571
METHOD FOR TESTING COMPRESSION PRESSURE 571
TEST BLOWBY PRESSURE 573
METHOD FOR TESTING BLOWBY PRESSURE 573
TEST ENGINE OIL PRESSURE 576
METHOD FOR TESTING ENGINE OIL PRESSURE 576
TEST EGR VALVE AND VGT OIL PRESSURE 577
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 577
TEST FUEL PRESSURE 579
METHOD FOR TESTING FUEL PRESSURE 580
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 586
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 587
BLEED AIR FROM FUEL SYSTEM 591
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 591
TEST FUEL CIRCUIT FOR LEAKAGE 593
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 593
HANDLE CYLINDER CUT-OUT MODE OPERATION 595
HANDLE NO-INJECTION CRANKING OPERATION 596
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 597
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 597
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 597
TEST ALTERNATOR BELT 598
METHOD FOR REMOVING ALTERNATOR BELT 598
TEST AUTOMATIC TENSIONER 599
METHOD FOR TESTING AUTOMATIC TENSIONER 599
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 601
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 601
TEST SCR RELATED FUNCTIONS 602
TEST AdBlue/DEF PUMP RAISED PRESSURE 606
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 609
TEST AdBlue/DEF LINE HEATER RELAY 1 614
TEST AdBlue/DEF LINE HEATER RELAY 2 617
TEST AdBlue/DEF PUMP HEATER RELAY 620
TEST AdBlue/DEF TANK HEATER VALVE 623
TEST DENITRATION EFFICIENCY OF SCR 626
CLEAN AdBlue/DEF TANK 629
METHOD FOR CLEANING AdBlue/DEF TANK 629
CLEAN AdBlue/DEF TANK MOUNTING PORTION 633
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 633
ADJUST DECELERATOR PEDAL 635
METHOD FOR ADJUSTING DECELERATOR PEDAL 635
POWER TRAIN 637
TEST POWER TRAIN OIL PRESSURE 637
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 638
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 649
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 649
TEST BRAKE PERFORMANCE SIMPLY 651
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 651
ADJUST BRAKE PEDAL 652
METHOD FOR ADJUSTING BRAKE PEDAL 652
ADJUST PARKING BRAKE LEVER 654
METHOD FOR ADJUSTING PARKING BRAKE LEVER 654
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL 656
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 656
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM 657
UNDERCARRIAGE AND FRAME 659
ADJUST IDLER CLEARANCE 659
METHOD FOR ADJUSTING IDLER CLEARANCE 659
TEST AND ADJUST TRACK TENSION 660
METHOD FOR TESTING TRACK TENSION 660
METHOD FOR ADJUSTING TRACK TENSION 660
HYDRAULIC SYSTEM 661
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 661
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 661
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 662
METHOD FOR TESTING WORK EQUIPMENT AND HSS OIL PRESSURES 662
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES 666
TEST OIL PRESSURE OF CONTROL CIRCUIT 667
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 667
TEST PPC VALVE OUTLET PRESSURE 669
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE 669
BLEED AIR FROM HSS PUMP 671
METHOD FOR BLEEDING AIR FROM HSS PUMP 671
TEST AND ADJUST PLAY OF WORK EQUIPMENT PPC VALVE 672
METHOD FOR TESTING PLAY OF WORK EQUIPMENT PPC VALVE 672
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 673
TEST COOLING FAN SPEED 674
METHOD FOR TESTING COOLING FAN SPEED 674
TEST COOLING FAN CIRCUIT OIL PRESSURE 675
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 675
BLEED AIR FROM COOLING FAN PUMP 677
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP 677
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 678
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 678
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 678
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 679
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 680
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 680
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 682
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 682
WORK EQUIPMENT 684
ADJUST WORK EQUIPMENT LOCK LEVER 684
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 684
CAB AND ITS ATTACHMENTS 685
TEST AND ADJUST OPERATOR’S CAB 685
METHOD FOR TESTING OPERATOR’S CAB 685
METHOD FOR ADJUSTING OPERATOR’S CAB 687
ELECTRICAL SYSTEM 690
SET AND OPERATE MACHINE MONITOR 690
OPERATOR MODE 694
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 694
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 694
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 695
CHECKING FUNCTION OF SERVICE METER 695
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 695
SERVICE MODE 698
METHOD FOR OPERATING SERVICE MODE 698
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 699
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 705
ABNORMALITY RECORD MENU 715
METHOD FOR CONFIRMING MAINTENANCE RECORD 719
METHOD FOR OPERATING MAINTENANCE MODE SETTING 720
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 724
DEFAULT MENU 726
DIAGNOSTIC TESTS MENU 733
ADJUSTMENT MENU 742
METHOD FOR PERFORMING NO-INJECTION CRANKING 771
KOMTRAX SETTINGS MENU 773
METHOD FOR DISPLAYING SERVICE MESSAGE 775
METHOD FOR STARTING UP KOMTRAX TERMINAL 777
ADJUST WHEN POWER TRAIN CONTROLLER IS REPLACED 782
METHOD FOR ADJUSTING WHEN POWER TRAIN CONTROLLER IS REPLACED 782
ADJUST REARVIEW CAMERA ANGLE 785
ADJUST REARVIEW CAMERA ANGLE 785
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 786
HANDLE BATTERY DISCONNECT SWITCH 787
TEST DIODES 788
METHOD FOR TESTING DIODE USING DIGITAL TESTER 788
METHOD FOR TESTING DIODE USING ANALOG TESTER 788
Pm CLINIC 789
Pm CLINIC SERVICE 789
Pm CLINIC CHECK SHEET: D65EX-18 791
Pm CLINIC CHECK SHEET: D65PX-18 803
Pm CLINIC CHECK SHEET: D65WX-18 815
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D65EX-18 827
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D65PX-18 834
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D65WX-18 840
40 TROUBLESHOOTING 847
CONTENTS 848
ABBREVIATION LIST 858
RELATED INFORMATION ON TROUBLESHOOTING 864
GENERAL TROUBLESHOOTING POINTS 864
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 865
SEQUENCE OF EVENTS IN TROUBLESHOOTING 877
CHECKS BEFORE TROUBLESHOOTING 879
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 881
WALK-AROUND CHECK 881
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 883
METHOD FOR CHECKING ELECTRIC EQUIPMENT 883
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 891
PROCEDURE FOR TROUBLESHOOTING 898
SYMPTOM AND TROUBLESHOOTING NUMBERS 901
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 904
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 906
CONNECTORS LIST AND LAYOUT 908
CONNECTOR CONTACT IDENTIFICATION 924
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 964
FUSE LOCATION TABLE 970
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 973
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 977
FAILURE CODES TABLE 979
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 997
FAILURE CODE [1500L0] 997
FAILURE CODE [15SAL1] 998
FAILURE CODE [15SALH] 1000
FAILURE CODE [15SBL1] 1002
FAILURE CODE [15SBLH] 1004
FAILURE CODE [15SEL1] 1006
FAILURE CODE [15SELH] 1008
FAILURE CODE [15SFL1] 1010
FAILURE CODE [15SFLH] 1012
FAILURE CODE [15SGL1] 1014
FAILURE CODE [15SGLH] 1016
FAILURE CODE [15SJL1] 1018
FAILURE CODE [15SJLH] 1020
FAILURE CODE [1800MW] 1022
FAILURE CODE [879AKA] 1023
FAILURE CODE [879AKB] 1024
FAILURE CODE [879BKA] 1025
FAILURE CODE [879BKB] 1027
FAILURE CODE [879CKA] 1029
FAILURE CODE [879CKB] 1030
FAILURE CODE [879DKZ] 1031
FAILURE CODE [879EMC] 1033
FAILURE CODE [879FMC] 1034
FAILURE CODE [879GKX] 1035
FAILURE CODE [989L00] 1037
FAILURE CODE [989M00] 1038
FAILURE CODE [989N00] 1039
FAILURE CODE [A1U0N3] 1040
FAILURE CODE [A1U0N4] 1042
FAILURE CODE [A900FR] 1044
FAILURE CODE [A900N6] 1045
FAILURE CODE [A900NY] 1046
FAILURE CODE [AA10NX] 1047
FAILURE CODE [AB00KE] 1049
FAILURE CODE [AQ10N3] 1051
FAILURE CODE [AS00N3] 1053
FAILURE CODE [AS00R2] 1055
FAILURE CODE [AS00R3] 1056
FAILURE CODE [AS00R4] 1057
FAILURE CODE [AS00R5] 1058
FAILURE CODE [AS00R6] 1059
FAILURE CODE [AS00ZK] 1060
FAILURE CODE [AS10KM] 1061
FAILURE CODE [AS10NR] 1062
FAILURE CODE [AS10NT] 1063
FAILURE CODE [B@BAZG] 1064
FAILURE CODE [B@BCNS] 1065
FAILURE CODE [B@BCQA] 1066
FAILURE CODE [B@BCZK] 1068
FAILURE CODE [B@CENS] 1070
FAILURE CODE [B@HANS] 1071
FAILURE CODE [CA115] 1072
FAILURE CODE [CA122] 1073
FAILURE CODE [CA123] 1075
FAILURE CODE [CA131] 1077
FAILURE CODE [CA132] 1079
FAILURE CODE [CA144] 1082
FAILURE CODE [CA145] 1084
FAILURE CODE [CA153] 1086
FAILURE CODE [CA154] 1089
FAILURE CODE [CA187] 1092
FAILURE CODE [CA221] 1094
FAILURE CODE [CA222] 1096
FAILURE CODE [CA227] 1098
FAILURE CODE [CA234] 1099
FAILURE CODE [CA238] 1100
FAILURE CODE [CA239] 1102
FAILURE CODE [CA249] 1104
FAILURE CODE [CA256] 1106
FAILURE CODE [CA271] 1108
FAILURE CODE [CA272] 1110
FAILURE CODE [CA281] 1112
FAILURE CODE [CA322] 1113
FAILURE CODE [CA323] 1115
FAILURE CODE [CA324] 1117
FAILURE CODE [CA325] 1119
FAILURE CODE [CA331] 1121
FAILURE CODE [CA332] 1123
FAILURE CODE [CA343] 1125
FAILURE CODE [CA351] 1126
FAILURE CODE [CA352] 1127
FAILURE CODE [CA356] 1130
FAILURE CODE [CA357] 1132
FAILURE CODE [CA386] 1134
FAILURE CODE [CA428] 1135
FAILURE CODE [CA429] 1137
FAILURE CODE [CA435] 1139
FAILURE CODE [CA441] 1141
FAILURE CODE [CA442] 1143
FAILURE CODE [CA449] 1144
FAILURE CODE [CA451] 1148
FAILURE CODE [CA452] 1151
FAILURE CODE [CA488] 1153
FAILURE CODE [CA515] 1154
FAILURE CODE [CA516] 1156
FAILURE CODE [CA553] 1158
FAILURE CODE [CA555] 1159
FAILURE CODE [CA556] 1160
FAILURE CODE [CA559] 1161
FAILURE CODE [CA595] 1165
FAILURE CODE [CA687] 1166
FAILURE CODE [CA689] 1168
FAILURE CODE [CA691] 1173
FAILURE CODE [CA692] 1175
FAILURE CODE [CA697] 1177
FAILURE CODE [CA698] 1178
FAILURE CODE [CA731] 1179
FAILURE CODE [CA778] 1181
FAILURE CODE [CA1117] 1186
FAILURE CODE [CA1664] 1187
FAILURE CODE [CA1669] 1190
FAILURE CODE [CA1673] 1191
FAILURE CODE [CA1677] 1192
FAILURE CODE [CA1678] 1193
FAILURE CODE [CA1682] 1194
FAILURE CODE [CA1683] 1199
FAILURE CODE [CA1684] 1201
FAILURE CODE [CA1686] 1203
FAILURE CODE [CA1691] 1204
FAILURE CODE [CA1694] 1207
FAILURE CODE [CA1695] 1210
FAILURE CODE [CA1696] 1211
FAILURE CODE [CA1712] 1213
FAILURE CODE [CA1713] 1216
FAILURE CODE [CA1714] 1218
FAILURE CODE [CA1715] 1219
FAILURE CODE [CA1776] 1220
FAILURE CODE [CA1777] 1223
FAILURE CODE [CA1843] 1226
FAILURE CODE [CA1844] 1228
FAILURE CODE [CA1879] 1231
FAILURE CODE [CA1881] 1234
FAILURE CODE [CA1883] 1237
FAILURE CODE [CA1885] 1241
FAILURE CODE [CA1887] 1243
FAILURE CODE [CA1921] 1245
FAILURE CODE [CA1922] 1248
FAILURE CODE [CA1942] 1253
FAILURE CODE [CA1993] 1254
FAILURE CODE [CA2185] 1257
FAILURE CODE [CA2186] 1259
FAILURE CODE [CA2249] 1261
FAILURE CODE [CA2265] 1262
FAILURE CODE [CA2266] 1264
FAILURE CODE [CA2271] 1266
FAILURE CODE [CA2272] 1269
FAILURE CODE [CA2288] 1272
FAILURE CODE [CA2311] 1273
FAILURE CODE [CA2349] 1274
FAILURE CODE [CA2353] 1277
FAILURE CODE [CA2357] 1279
FAILURE CODE [CA2381] 1280
FAILURE CODE [CA2382] 1283
FAILURE CODE [CA2383] 1286
FAILURE CODE [CA2386] 1289
FAILURE CODE [CA2387] 1291
FAILURE CODE [CA2555] 1292
FAILURE CODE [CA2556] 1295
FAILURE CODE [CA2637] 1298
FAILURE CODE [CA2639] 1300
FAILURE CODE [CA2771] 1303
FAILURE CODE [CA2777] 1309
FAILURE CODE [CA2976] 1312
FAILURE CODE [CA3133] 1314
FAILURE CODE [CA3134] 1316
FAILURE CODE [CA3135] 1318
FAILURE CODE [CA3142] 1322
FAILURE CODE [CA3143] 1323
FAILURE CODE [CA3144] 1324
FAILURE CODE [CA3146] 1326
FAILURE CODE [CA3147] 1327
FAILURE CODE [CA3148] 1328
FAILURE CODE [CA3151] 1330
FAILURE CODE [CA3165] 1336
FAILURE CODE [CA3229] 1338
FAILURE CODE [CA3231] 1340
FAILURE CODE [CA3232] 1342
FAILURE CODE [CA3235] 1346
FAILURE CODE [CA3239] 1348
FAILURE CODE [CA3241] 1351
FAILURE CODE [CA3242] 1354
FAILURE CODE [CA3251] 1357
FAILURE CODE [CA3253] 1359
FAILURE CODE [CA3254] 1362
FAILURE CODE [CA3255] 1365
FAILURE CODE [CA3256] 1368
FAILURE CODE [CA3311] 1370
FAILURE CODE [CA3312] 1372
FAILURE CODE [CA3313] 1375
FAILURE CODE [CA3314] 1376
FAILURE CODE [CA3315] 1377
FAILURE CODE [CA3316] 1380
FAILURE CODE [CA3317] 1381
FAILURE CODE [CA3318] 1382
FAILURE CODE [CA3319] 1385
FAILURE CODE [CA3321] 1386
FAILURE CODE [CA3322] 1388
FAILURE CODE [CA3419] 1391
FAILURE CODE [CA3421] 1393
FAILURE CODE [CA3497] 1395
FAILURE CODE [CA3498] 1396
FAILURE CODE [CA3543] 1397
FAILURE CODE [CA3545] 1404
FAILURE CODE [CA3547] 1406
FAILURE CODE [CA3558] 1407
FAILURE CODE [CA3559] 1409
FAILURE CODE [CA3562] 1411
FAILURE CODE [CA3563] 1413
FAILURE CODE [CA3567] 1416
FAILURE CODE [CA3568] 1419
FAILURE CODE [CA3571] 1426
FAILURE CODE [CA3572] 1428
FAILURE CODE [CA3574] 1430
FAILURE CODE [CA3575] 1432
FAILURE CODE [CA3577] 1434
FAILURE CODE [CA3578] 1436
FAILURE CODE [CA3582] 1438
FAILURE CODE [CA3583] 1446
FAILURE CODE [CA3596] 1448
FAILURE CODE [CA3649] 1451
FAILURE CODE [CA3681] 1453
FAILURE CODE [CA3682] 1455
FAILURE CODE [CA3713] 1458
FAILURE CODE [CA3717] 1461
FAILURE CODE [CA3718] 1462
FAILURE CODE [CA3725] 1463
FAILURE CODE [CA3741] 1466
FAILURE CODE [CA3748] 1467
FAILURE CODE [CA3751] 1470
FAILURE CODE [CA3755] 1472
FAILURE CODE [CA3866] 1474
FAILURE CODE [CA3867] 1478
FAILURE CODE [CA3868] 1481
FAILURE CODE [CA3899] 1485
FAILURE CODE [CA3911] 1487
FAILURE CODE [CA3912] 1491
FAILURE CODE [CA3932] 1493
FAILURE CODE [CA3933] 1495
FAILURE CODE [CA3934] 1497
FAILURE CODE [CA3935] 1500
FAILURE CODE [CA3936] 1502
FAILURE CODE [CA4151] 1504
FAILURE CODE [CA4152] 1508
FAILURE CODE [CA4155] 1512
FAILURE CODE [CA4156] 1515
FAILURE CODE [CA4157] 1518
FAILURE CODE [CA4158] 1520
FAILURE CODE [CA4159] 1521
FAILURE CODE [CA4161] 1522
FAILURE CODE [CA4162] 1524
FAILURE CODE [CA4163] 1527
FAILURE CODE [CA4164] 1529
FAILURE CODE [CA4165] 1531
FAILURE CODE [CA4166] 1533
FAILURE CODE [CA4168] 1535
FAILURE CODE [CA4169] 1538
FAILURE CODE [CA4171] 1540
FAILURE CODE [CA4249] 1543
FAILURE CODE [CA4251] 1545
FAILURE CODE [CA4259] 1547
FAILURE CODE [CA4261] 1550
FAILURE CODE [CA4277] 1553
FAILURE CODE [CA4281] 1557
FAILURE CODE [CA4459] 1561
FAILURE CODE [CA4461] 1564
FAILURE CODE [CA4658] 1567
FAILURE CODE [CA4731] 1571
FAILURE CODE [CA4732] 1572
FAILURE CODE [CA4739] 1573
FAILURE CODE [CA4768] 1574
FAILURE CODE [CA4769] 1576
FAILURE CODE [CA4842] 1579
FAILURE CODE [CA4952] 1583
FAILURE CODE [CA5115] 1585
FAILURE CODE [CA5383] 1588
FAILURE CODE [D130KA] 1590
FAILURE CODE [D130KB] 1593
FAILURE CODE [D19JKZ] 1595
FAILURE CODE [D811MC] 1598
FAILURE CODE [D862KA] 1599
FAILURE CODE [D8ALKA] 1600
FAILURE CODE [D8ALKB] 1602
FAILURE CODE [D8AQKR] 1604
FAILURE CODE [DAF0MB] 1606
FAILURE CODE [DAF0MC] 1607
FAILURE CODE [DAF8KB] 1608
FAILURE CODE [DAF9KQ] 1609
FAILURE CODE [DAFGMC] 1610
FAILURE CODE [DAFLKA] 1611
FAILURE CODE [DAFLKB] 1613
FAILURE CODE [DAFQKR] 1615
FAILURE CODE [DAQW00] 1616
FAILURE CODE [DAZ9KQ] 1617
FAILURE CODE [DAZQKR] 1618
FAILURE CODE [DB2QKR] 1619
FAILURE CODE [DB2RKR] 1624
FAILURE CODE [DBE0KT] 1629
FAILURE CODE [DBE1KK] 1630
FAILURE CODE [DBE2KK] 1633
FAILURE CODE [DBE5KK] 1636
FAILURE CODE [DBE6KK] 1638
FAILURE CODE [DBE7KK] 1640
FAILURE CODE [DBE9KQ] 1642
FAILURE CODE [DBELKA] 1643
FAILURE CODE [DBELKB] 1645
FAILURE CODE [DBEQKR] 1647
FAILURE CODE [DBERKR] 1648
FAILURE CODE [DD12KA] 1650
FAILURE CODE [DD12KB] 1652
FAILURE CODE [DD13KA] 1654
FAILURE CODE [DD13KB] 1656
FAILURE CODE [DD14KA] 1658
FAILURE CODE [DD14KB] 1660
FAILURE CODE [DDKFL4] 1662
FAILURE CODE [DDKGL4] 1664
FAILURE CODE [DDKHKA] 1666
FAILURE CODE [DDKHKB] 1668
FAILURE CODE [DDN7KA] 1670
FAILURE CODE [DDN7KB] 1672
FAILURE CODE [DDNLKA] 1674
FAILURE CODE [DDNLKB] 1676
FAILURE CODE [DGS1KA] 1678
FAILURE CODE [DGS1KX] 1680
FAILURE CODE [DGT1KA] 1682
FAILURE CODE [DGT1KX] 1685
FAILURE CODE [DH21KA] 1687
FAILURE CODE [DH21KY] 1689
FAILURE CODE [DHA4KA] 1691
FAILURE CODE [DHAAMA] 1693
FAILURE CODE [DHACMA] 1695
FAILURE CODE [DHTDKA] 1697
FAILURE CODE [DHTDKY] 1699
FAILURE CODE [DK10KA] 1701
FAILURE CODE [DK10KB] 1704
FAILURE CODE [DK30KA] 1706
FAILURE CODE [DK30KX] 1709
FAILURE CODE [DK30KY] 1710
FAILURE CODE [DK30KZ] 1712
FAILURE CODE [DK30L8] 1713
FAILURE CODE [DK31KA] 1714
FAILURE CODE [DK31KY] 1717
FAILURE CODE [DK40KA] 1719
FAILURE CODE [DK40KY] 1721
FAILURE CODE [DK55KX] 1723
FAILURE CODE [DK55KZ] 1724
FAILURE CODE [DK55L8] 1725
FAILURE CODE [DK56KA] 1726
FAILURE CODE [DK56KY] 1728
FAILURE CODE [DK57KA] 1730
FAILURE CODE [DK57KY] 1732
FAILURE CODE [DKH1KA] 1734
FAILURE CODE [DKH1KY] 1737
FAILURE CODE [DLM3KA] 1739
FAILURE CODE [DLM3MB] 1741
FAILURE CODE [DLT3KA] 1742
FAILURE CODE [DLT3KB] 1744
FAILURE CODE [DR21KX] 1746
FAILURE CODE [DR31KX] 1747
FAILURE CODE [DV20KB] 1748
FAILURE CODE [DW5AKA] 1750
FAILURE CODE [DW5AKB] 1752
FAILURE CODE [DW5AKY] 1754
FAILURE CODE [DW7BKA] 1756
FAILURE CODE [DW7BKB] 1758
FAILURE CODE [DW7BKY] 1760
FAILURE CODE [DWN1KA] 1761
FAILURE CODE [DWN1KB] 1763
FAILURE CODE [DWN1KY] 1765
FAILURE CODE [DWN2KA] 1767
FAILURE CODE [DWN2KB] 1769
FAILURE CODE [DWN2KY] 1771
FAILURE CODE [DWN5KA] 1772
FAILURE CODE [DWN5KB] 1774
FAILURE CODE [DWN5KY] 1775
FAILURE CODE [DXA2KA] 1777
FAILURE CODE [DXA2KB] 1779
FAILURE CODE [DXA2KY] 1781
FAILURE CODE [DXH1KA] 1782
FAILURE CODE [DXH1KB] 1784
FAILURE CODE [DXH1KY] 1786
FAILURE CODE [DXH4KA] 1788
FAILURE CODE [DXH4KB] 1790
FAILURE CODE [DXH4KY] 1792
FAILURE CODE [DXH5KA] 1794
FAILURE CODE [DXH5KB] 1796
FAILURE CODE [DXH5KY] 1798
FAILURE CODE [DXH6KA] 1800
FAILURE CODE [DXH6KB] 1802
FAILURE CODE [DXH6KY] 1804
FAILURE CODE [DXH7KA] 1806
FAILURE CODE [DXH7KB] 1808
FAILURE CODE [DXH7KY] 1810
FAILURE CODE [DXH8KA] 1812
FAILURE CODE [DXH8KB] 1814
FAILURE CODE [DXH8KY] 1816
FAILURE CODE [DXJ4KA] 1818
FAILURE CODE [DXJ4KB] 1820
FAILURE CODE [DXJCKA] 1822
FAILURE CODE [DXJCKB] 1824
FAILURE CODE [DXJCKY] 1826
FAILURE CODE [DXJDKA] 1828
FAILURE CODE [DXJDKB] 1830
FAILURE CODE [DXJDKY] 1832
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1834
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1834
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1841
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1844
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1846
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1848
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP 1852
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1853
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1854
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1856
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1857
E-11 POWER TRAIN OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1858
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1859
E-13 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1860
E-14 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 1861
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1864
E-16 POWER TRAIN OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1866
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1867
E-18 OPERATION MODE DOES NOT CHANGE 1868
E-19 GEAR SHIFT MODE DOES NOT CHANGE 1869
E-20 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 1870
E-21 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 1871
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1872
E-23 REVERSE SLOW MODE DOES NOT FUNCTION PROPERLY 1873
E-24 ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP SOUNDING 1874
E-25 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1875
E-26 SERVICE MODE CANNOT BE SELECTED 1876
E-27 HORN DOES NOT SOUND 1877
E-28 HORN DOES NOT STOP SOUNDING 1879
E-29 BACKUP ALARM DOES NOT SOUND 1880
E-30 BACKUP ALARM DOES NOT STOP SOUNDING 1882
E-31 HEADLAMP DOES NOT LIGHT UP 1883
E-32 REAR LAMP DOES NOT LIGHT UP 1887
E-33 ALL WIPERS DO NOT OPERATE 1890
E-34 FRONT WIPER DOES NOT OPERATE 1894
E-35 REAR WIPER DOES NOT OPERATE 1897
E-36 LEFT DOOR WIPER DOES NOT OPERATE 1900
E-37 RIGHT DOOR WIPER DOES NOT OPERATE 1903
E-38 FRONT WASHER DOES NOT OPERATE 1906
E-39 REAR WASHER DOES NOT OPERATE 1908
E-40 LEFT DOOR WASHER DOES NOT OPERATE 1910
E-41 RIGHT DOOR WASHER DOES NOT OPERATE 1912
E-42 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1914
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1915
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1915
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1916
FAILURE MODE AND CAUSE TABLE 1918
H-1 MACHINE LACKS POWER (INSUFFICIENT DRAWBAR PULL) 1926
H-2 MACHINE DOES NOT TRAVEL (AT 2ND OR 3RD GEAR SPEED) 1928
H-3 MACHINE DOES NOT MOVE OFF AT ALL GEAR SPEEDS 1929
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION, EITHER FORWARD OR IN REVERSE 1931
H-5 LARGE TIME LAG IS IN GEAR SHIFTING OR DIRECTIONAL CHANGE 1932
H-6 BRAKE DOES NOT WORK 1934
H-7 POWER TRAIN OIL OVERHEATS 1935
H-8 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND HSS PUMP OR HSS MOTOR 1937
H-9 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 1938
H-10 MACHINE CANNOT BE STEERED (MACHINE DOES NOT TURN LEFT OR RIGHT) 1939
H-11 STEERING SPEED OR POWER IS INSUFFICIENT 1940
H-12 ALL WORK EQUIPMENTS OPERATE SLOWLY 1941
H-13 ALL WORK EQUIPMENTS DO NOT OPERATE 1942
H-14 BLADE LIFT SPEED OR POWER IS LOW 1943
H-15 BLADE TILT SPEED OR POWER IS LOW 1944
H-16 BLADE ANGLE SPEED OR POWER IS LOW 1945
H-17 RIPPER LIFT SPEED OR POWER IS LOW 1946
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 1947
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 1948
H-20 HYDRAULIC DRIFT OF LIFTED RIPPER IS LARGE 1949
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1950
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1952
TROUBLESHOOTING OF ENGINE (S-MODE) 1953
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1953
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1954
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1955
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1956
S-4 ENGINE STARTABILITY IS POOR 1958
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1960
S-6 ENGINE STOPS DURING OPERATION 1962
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1964
S-8 ENGINE LACKS POWER 1965
S-9 KDPF GETS CLOGGED IN A SHORT TIME 1967
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1969
S-11 OIL BECOMES CONTAMINATED QUICKLY 1970
S-12 FUEL CONSUMPTION IS EXCESSIVE 1971
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1972
S-14 OIL PRESSURE DROPS 1973
S-15 FUEL MIXES INTO ENGINE OIL 1975
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1976
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1977
S-18 UNUSUAL NOISE IS HEARD 1978
S-19 VIBRATION IS EXCESSIVE 1979
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1980
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1981
S-22 ACTIVE REGENERATION TAKES TIME 1983
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1984
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1985
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1987
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1988
50 DISASSEMBLY AND ASSEMBLY 1989
CONTENTS 1990
ABBREVIATION LIST 1996
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2002
HOW TO READ THIS MANUAL 2002
COATING MATERIALS LIST 2004
SPECIAL TOOLS LIST 2008
SKETCHES OF SPECIAL TOOLS 2030
ENGINE AND COOLING SYSTEM 2051
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2051
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2051
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2055
REMOVE AND INSTALL INJECTOR ASSEMBLY 2060
METHOD FOR REMOVING INJECTOR ASSEMBLY 2061
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2068
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2079
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2080
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2090
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2106
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2106
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2107
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2108
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2108
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2109
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2111
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2111
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2113
REMOVE AND INSTALL ALTERNATOR BELT 2115
METHOD FOR REMOVING ALTERNATOR BELT 2115
METHOD FOR INSTALLING ALTERNATOR BELT 2116
REMOVE AND INSTALL AUTOMATIC TENSIONER 2118
METHOD FOR REMOVING AUTOMATIC TENSIONER 2118
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2118
REMOVE AND INSTALL RADIATOR ASSEMBLY 2119
METHOD FOR REMOVING RADIATOR ASSEMBLY 2119
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2122
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2126
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2126
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2128
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2131
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2131
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2133
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY 2136
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2136
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2138
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2141
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2141
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2142
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2144
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2144
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2146
REMOVE AND INSTALL ENGINE ASSEMBLY 2148
METHOD FOR REMOVING ENGINE ASSEMBLY 2148
METHOD FOR INSTALLING ENGINE ASSEMBLY 2152
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2158
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2158
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2160
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2164
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2164
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2168
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2176
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2176
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2179
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2182
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2182
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2184
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2186
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2187
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2191
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2195
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2196
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2201
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2207
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2207
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2208
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2215
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2215
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2215
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2216
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2216
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2217
REMOVE AND INSTALL KDPF ASSEMBLY 2220
METHOD FOR REMOVING KDPF ASSEMBLY 2220
METHOD FOR INSTALLING KDPF ASSEMBLY 2224
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2228
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2228
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2232
REMOVE AND INSTALL SCR ASSEMBLY 2238
METHOD FOR REMOVING SCR ASSEMBLY 2238
METHOD FOR INSTALLING SCR ASSEMBLY 2240
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2243
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2243
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2250
REMOVE AND INSTALL KCCV ASSEMBLY 2257
METHOD FOR REMOVING KCCV ASSEMBLY 2257
METHOD FOR INSTALLING KCCV ASSEMBLY 2259
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2261
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2261
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2264
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2269
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2269
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2272
REMOVE AND INSTALL AdBlue/DEF PUMP 2276
METHOD FOR REMOVING AdBlue/DEF PUMP 2276
METHOD FOR INSTALLING AdBlue/DEF PUMP 2279
REMOVE AND INSTALL AdBlue/DEF HOSE 2282
METHOD FOR REMOVING AdBlue/DEF HOSE 2282
METHOD FOR INSTALLING AdBlue/DEF HOSE 2287
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2292
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2292
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2293
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2295
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2295
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2297
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2300
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2300
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2302
POWER TRAIN 2304
REMOVE AND INSTALL DAMPER ASSEMBLY 2304
METHOD FOR REMOVING DAMPER ASSEMBLY 2304
METHOD FOR INSTALLING DAMPER ASSEMBLY 2307
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY 2312
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY 2312
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY 2317
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY 2323
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY 2323
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY 2328
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY 2334
METHOD FOR DISASSEMBLING PTO ASSEMBLY 2334
METHOD FOR ASSEMBLING PTO ASSEMBLY 2337
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2341
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2342
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2348
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2357
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2358
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY 2376
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY 2389
METHOD FOR DISASSEMBLING HSS ASSEMBLY 2391
METHOD FOR ASSEMBLING HSS ASSEMBLY 2402
REMOVAL AND INSTALLATION OF HSS MOTOR 2419
METHOD FOR REMOVING HSS MOTOR ASSEMBLY 2419
METHOD FOR INSTALLING HSS MOTOR ASSEMBLY 2421
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY 2424
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2424
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY 2427
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2430
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2432
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2439
UNDERCARRIAGE AND FRAME 2449
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2449
METHOD FOR REMOVING TRACK FRAME ASSEMBLY 2449
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY 2451
REMOVE AND INSTALL IDLER ASSEMBLY 2454
METHOD FOR REMOVING IDLER ASSEMBLY 2454
METHOD FOR INSTALLING IDLER ASSEMBLY 2455
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2457
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2457
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2459
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2463
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2463
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2463
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2465
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2465
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2468
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2471
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2471
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2471
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2473
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2473
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2475
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2478
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2478
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2479
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2480
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2480
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2481
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2484
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2484
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2485
SEPARATE AND CONNECT TRACK ASSEMBLY 2486
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY 2486
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2486
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2487
METHOD FOR CONNECTING TRACK ASSEMBLY 2488
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2490
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2490
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2490
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2491
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2491
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2494
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2506
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2507
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2508
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2523
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2524
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2525
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2532
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2533
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2535
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2539
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 2539
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 2540
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS 2542
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS 2542
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS 2542
HYDRAULIC SYSTEM 2544
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2544
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2544
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2547
REMOVE AND INSTALL HSS PUMP AND COOLING FAN PUMP ASSEMBLY 2552
METHOD FOR REMOVING HSS PUMP AND COOLING FAN PUMP ASSEMBLY 2552
METHOD FOR INSTALLING HSS PUMP AND COOLING FAN PUMP ASSEMBLY 2553
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2556
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2556
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2558
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY 2561
METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY 2561
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY 2561
REMOVE AND INSTALL 5 SPOOL CONTROL VALVE ASSEMBLY 2563
METHOD FOR REMOVING 5 SPOOL CONTROL VALVE ASSEMBLY 2563
METHOD FOR INSTALLING 5 SPOOL CONTROL VALVE ASSEMBLY 2565
REMOVE AND INSTALL 4 SPOOL CONTROL VALVE ASSEMBLY 2568
METHOD FOR REMOVING 4 SPOOL CONTROL VALVE ASSEMBLY 2568
METHOD FOR INSTALLING 4 SPOOL CONTROL VALVE ASSEMBLY 2570
DISASSEMBLE AND ASSEMBLE BLADE PPC VALVE 2574
METHOD FOR DISASSEMBLING BLADE PPC VALVE 2574
METHOD FOR ASSEMBLING BLADE PPC VALVE 2574
DISASSEMBLE AND ASSEMBLE RIPPER PPC VALVE 2576
METHOD FOR DISASSEMBLING RIPPER PPC VALVE 2576
METHOD FOR ASSEMBLING RIPPER PPC VALVE 2576
WORK EQUIPMENT 2578
REMOVE AND INSTALL STRAIGHT TILT POWER PITCH DOZER BLADE ASSEMBLY 2578
METHOD FOR REMOVING STRAIGHT TILT POWER PITCH DOZER BLADE ASSEMBLY 2578
METHOD FOR INSTALLING STRAIGHT TILT POWER PITCH DOZER BLADE ASSEMBLY 2580
REMOVE AND INSTALL POWER ANGLE POWER TILT DOZER BLADE ASSEMBLY 2584
METHOD FOR REMOVING POWER ANGLE POWER TILT DOZER BLADE ASSEMBLY 2584
METHOD FOR INSTALLING POWER ANGLE POWER TILT DOZER BLADE ASSEMBLY 2586
REMOVE AND INSTALL RIPPER ASSEMBLY 2589
METHOD FOR REMOVING RIPPER ASSEMBLY 2589
METHOD FOR INSTALLING RIPPER ASSEMBLY 2592
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2595
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2596
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2599
CAB AND ITS ATTACHMENTS 2603
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2603
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2603
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2610
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2619
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2619
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2620
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2625
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2625
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2630
REMOVE AND INSTALL OPERATOR’S SEAT 2636
METHOD FOR REMOVING OPERATOR’S SEAT 2636
METHOD FOR INSTALLING OPERATOR’S SEAT 2638
REMOVE AND INSTALL SEAT BELT 2640
METHOD FOR REMOVING SEAT BELT 2640
METHOD FOR INSTALLING SEAT BELT 2641
ELECTRICAL SYSTEM 2642
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2642
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2642
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2643
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY 2646
METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY 2646
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY 2647
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2649
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2649
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2650
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2652
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2652
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2653
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2654
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2654
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2654
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2656
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2656
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2658
REMOVE AND INSTALL REARVIEW CAMERA 2660
METHOD FOR REMOVING REARVIEW CAMERA 2660
METHOD FOR INSTALLING REARVIEW CAMERA 2660
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2662
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2662
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2664
60 MAINTENANCE STANDARD 2667
CONTENTS 2668
ABBREVIATION LIST 2670
ENGINE AND COOLING SYSTEM 2676
MAINTENANCE STANDARD OF ENGINE MOUNT 2676
MAINTENANCE STANDARD OF DAMPER 2677
MAINTENANCE STANDARD OF COOLING SYSTEM 2679
MAINTENANCE STANDARD OF COOLING FAN PUMP 2681
MAINTENANCE STANDARD OF SERVO VALVE 2682
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2683
POWER TRAIN 2685
MAINTENANCE STANDARD OF UNIVERSAL JOINT 2685
MAINTENANCE STANDARD OF POWER TRAIN MOUNT 2686
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 2688
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 2691
MAINTENANCE STANDARD OF TRANSMISSION 2692
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 2697
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 2698
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 2699
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE 2700
MAINTENANCE STANDARD OF BEVEL GEAR SHAFT, HSS, AND BRAKE 2701
MAINTENANCE STANDARD OF BRAKE VALVE 2706
MAINTENANCE STANDARD OF FINAL DRIVE 2708
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 2711
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 2712
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2714
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 2715
UNDERCARRIAGE AND FRAME 2717
MAINTENANCE STANDARD OF MAIN FRAME 2717
MAINTENANCE STANDARD OF SUSPENSION 2718
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2720
MAINTENANCE STANDARD OF IDLER 2722
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2724
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2725
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2726
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2727
MAINTENANCE STANDARD OF SINGLE SHOE 2729
MAINTENANCE STANDARD OF SWAMP SHOE 2730
HYDRAULIC SYSTEM 2731
MAINTENANCE STANDARD OF HYDRAULIC TANK 2731
MAINTENANCE STANDARD OF SCAVENGING PUMP 2732
MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 2733
MAINTENANCE STANDARD OF WORK EQUIPMENT AND HSS PUMP 2734
MAINTENANCE STANDARD OF PC-EPC VALVE 2735
MAINTENANCE STANDARD OF HSS MOTOR 2736
MAINTENANCE STANDARD OF CONTROL VALVE 2738
MAINTENANCE STANDARD OF BLADE PPC VALVE 2746
MAINTENANCE STANDARD OF RIPPER PPC VALVE 2748
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE 2750
MAINTENANCE STANDARD OF QUICK DROP VALVE 2751
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE (FOR TILT DOZER AND ANGLE DOZER SERIES) 2753
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE (FOR POWER TILT PITCH DOZER SERIES) 2754
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE (FOR POWER ANGLE POWER TILT DOZER SERIES) 2755
WORK EQUIPMENT 2756
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT (FOR TILT DOZER AND POWER TILT PITCH DOZER SERIES) 2756
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT (FOR POWER ANGLE POWER TILT DOZER SERIES) 2759
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT (ANGLE DOZER SERIES) 2762
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 2765
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER (FOR TILT DOZER AND POWER TILT PITCH DOZER, AND ANGLE DOZER SERIES) 2767
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER (FOR POWER ANGLE POWER TILT DOZER SERIES) 2768
MAINTENANCE STANDARD OF BLADE TILT CYLINDER (FOR TILT DOZER AND POWER TILT PITCH DOZER, AND ANGLE DOZER SERIES) 2769
MAINTENANCE STANDARD OF BLADE TILT CYLINDER (FOR POWER ANGLE POWER TILT DOZER SERIES) 2770
MAINTENANCE STANDARD OF BLADE PITCH CYLINDER (FOR POWER TILT PITCH DOZER SERIES) 2771
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER (FOR POWER ANGLE POWER TILT DOZER SERIES) 2772
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 2773
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 2774
CAB AND ITS ATTACHMENTS 2775
MAINTENANCE STANDARD OF CAB MOUNT 2775
80 APPENDIX 2777
CONTENTS 2778
ABBREVIATION LIST 2780
AIR CONDITIONER SYSTEM 2786
PRECAUTIONS FOR REFRIGERANT 2786
AIR CONDITIONER COMPONENT 2787
SPECIFICATIONS OF AIR CONDITIONER 2789
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2790
OUTLINE OF REFRIGERATION CYCLE 2791
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2793
AIR CONDITIONER UNIT 2793
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2793
FUNCTION OF AIR CONDITIONER UNIT 2795
COMPONENT PARTS OF AIR CONDITIONER UNIT 2797
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2798
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2798
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2798
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2798
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2799
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2799
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2799
FUNCTION OF DUAL PRESSURE SWITCH 2800
AIR CONDITIONER CONTROLLER 2801
STRUCTURE OF AIR CONDITIONER CONTROLLER 2801
COMPRESSOR 2802
STRUCTURE OF COMPRESSOR 2802
SPECIFICATIONS OF COMPRESSOR 2802
FUNCTION OF COMPRESSOR 2802
CONDENSER 2803
STRUCTURE OF STANDARD CORE CONDENSER 2803
SPECIFICATIONS OF STANDARD CORE CONDENSER 2803
FUNCTION OF STANDARD CORE CONDENSER 2803
STRUCTURE OF WIDE CORE CONDENSER 2804
SPECIFICATIONS OF WIDE CORE CONDENSER 2804
FUNCTION OF WIDE CORE CONDENSER 2804
RECEIVER DRIER 2805
STRUCTURE OF RECEIVER DRIER 2805
SPECIFICATIONS OF RECEIVER DRIER 2805
FUNCTION OF RECEIVER DRIER 2805
SENSORS FOR AIR CONDITIONER SYSTEM 2806
STRUCTURE OF SUNLIGHT SENSOR 2806
FUNCTION OF SUNLIGHT SENSOR 2806
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2806
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2806
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2808
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2810
AIR CONDITIONER SYSTEM DIAGRAM 2812
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2813
FUNCTION OF AIR CONDITIONER CONTROLLER 2814
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2815
TESTING AIR LEAKAGE (DUCT) 2824
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2824
EXPLANATION FOR TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2827
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2828
TEST VENT (MODE) CHANGEOVER 2829
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2829
TESTING FRESH/RECIRC AIR CHANGEOVER 2830
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2830
TEST SUNLIGHT SENSOR 2831
METHOD FOR TESTING SUNLIGHT SENSOR 2831
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2832
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2832
TEST RELAYS 2833
METHOD FOR TESTING RELAYS 2833
AIR CONDITIONER TROUBLESHOOTING CHART 1 2834
AIR CONDITIONER TROUBLESHOOTING CHART 2 2835
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2838
FAILURE CODE [879AKA] 2840
FAILURE CODE [879AKB] 2841
FAILURE CODE [879BKA] 2842
FAILURE CODE [879BKB] 2844
FAILURE CODE [879CKA] 2846
FAILURE CODE [879CKB] 2847
FAILURE CODE [879DKZ] 2848
FAILURE CODE [879EMC] 2850
FAILURE CODE [879FMC] 2851
FAILURE CODE [879GKX] 2852
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2854
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2856
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2860
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2862
TROUBLESHOOTING USING GAUGE PRESSURE 2864
CONNECTION OF SERVICE TOOL 2867
METHOD FOR CONNECTING SERVICE TOOL 2867
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2869
HANDLE COMPRESSOR OIL 2871
90 CIRCUIT DIAGRAMS 2873
CONTENTS 2874
ABBREVIATION LIST 2875
HYDRAULIC CIRCUIT DIAGRAM 2881
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2881
HYDRAULIC CIRCUIT DIAGRAM (FOR STRAIGHT TILT AND SIGMA DOZER) 2885
HYDRAULIC CIRCUIT DIAGRAM (FOR STRAIGHT TILT POWER PITCH DOZER) 2887
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER ANGLE POWER TILT DOZER) 2889
HYDRAULIC CIRCUIT DIAGRAM (FOR STRAIGHT TILT AND SIGMA DOZER) (3D MACHINE CONTROL SPEC) 2891
HYDRAULIC CIRCUIT DIAGRAM (FOR STRAIGHT TILT POWER PITCH DOZER) (3D MACHINE CONTROL SPEC) 2893
HYDRAULIC CIRCUIT DIAGRAM (FOR POWER ANGLE POWER TILT DOZER) (3D MACHINE CONTROL SPEC) 2895
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 2897
ELECTRICAL CIRCUIT DIAGRAM 2899
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2899
ELECTRICAL CIRCUIT DIAGRAM (1/15) 2903
ELECTRICAL CIRCUIT DIAGRAM (2/15) 2905
ELECTRICAL CIRCUIT DIAGRAM (3/15) 2907
ELECTRICAL CIRCUIT DIAGRAM (4/15) 2909
ELECTRICAL CIRCUIT DIAGRAM (5/15) 2911
ELECTRICAL CIRCUIT DIAGRAM (6/15) 2913
ELECTRICAL CIRCUIT DIAGRAM (7/15) 2915
ELECTRICAL CIRCUIT DIAGRAM (8/15) 2917
ELECTRICAL CIRCUIT DIAGRAM (9/15) 2919
ELECTRICAL CIRCUIT DIAGRAM (10/15) 2921
ELECTRICAL CIRCUIT DIAGRAM (11/15) 2923
ELECTRICAL CIRCUIT DIAGRAM (12/15) 2925
ELECTRICAL CIRCUIT DIAGRAM (13/15) 2927
ELECTRICAL CIRCUIT DIAGRAM (14/15) 2929
ELECTRICAL CIRCUIT DIAGRAM (15/15) 2931
INDEX 2933

IMAGES PREVIEW OF THE MANUAL:

S.V 27/12/24