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

Description

Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06505-11 – PDF DOWNLOAD

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Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06505-11 – PDF DOWNLOAD 

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

DESCRIPTION:

Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06505-11 – PDF DOWNLOAD 

SERIAL NUMBERS
D65EX- 90001 and up
D65PX- 90001 and up
D65WX-90001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06505-11 – PDF DOWNLOAD 

SERIAL NUMBERS
D65EX- 90001 and up
D65PX- 90001 and up
D65WX-90001 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 159
COMPONENT PARTS OF UREA SCR SYSTEM 173
AdBlue/DEF MIXING TUBE 173
SCR ASSEMBLY 173
AdBlue/DEF TANK 176
AdBlue/DEF PUMP 178
AdBlue/DEF INJECTOR 179
AdBlue/DEF HOSE 180
AdBlue/DEF TANK HEATING VALVE 181
BOOT-UP SYSTEM 182
LAYOUT DRAWING OF BOOT-UP SYSTEM 182
SYSTEM OPERATING LAMP SYSTEM 184
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 184
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 184
BATTERY DISCONNECT SWITCH 186
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 186
FUNCTION OF BATTERY DISCONNECT SWITCH 186
ENGINE SYSTEM 188
LAYOUT DRAWING OF ENGINE SYSTEM 188
ENGINE CONTROL SYSTEM 190
LAYOUT OF ENGINE CONTROL SYSTEM 190
ENGINE CONTROL SYSTEM DIAGRAM 191
FUNCTION OF ENGINE CONTROL SYSTEM 193
AUTOMATIC IDLE STOP SYSTEM 195
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 195
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 195
COMPONENT PARTS OF ENGINE SYSTEM 198
DAMPER 198
VGT 199
EGR SYSTEM 203
EGR VALVE 205
EGR COOLER 207
KCCV SYSTEM 208
KCCV VENTILATOR 210
KDPF 212
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 257
POWER TRAIN CONTROLLER 259
ENGINE CONTROLLER 263
HYDRAULIC SYSTEM 270
LAYOUT DRAWING OF HYDRAULIC SYSTEM 270
CLSS 271
STRUCTURE OF CLSS 271
FUNCTION OF CLSS 272
COMPONENT PARTS OF HYDRAULIC SYSTEM 274
HYDRAULIC TANK 274
WORK EQUIPMENT AND HSS PUMP 275
LS VALVE 280
PC VALVE 285
PC-EPC VALVE 290
CONTROL VALVE 294
POWER TRAIN SYSTEM 327
LAYOUT DRAWING OF POWER TRAIN SYSTEM 327
OPERATION OF POWER TRAIN SYSTEM 330
TRANSMISSION, STEERING, AND BRAKE CONTROL 331
LAYOUT DRAWING OF TRANSMISSION, STEERING, AND BRAKE CONTROL SYSTEM 331
FUNCTION OF TRANSMISSION, STEERING, AND BRAKE CONTROL 332
PALM COMMAND CONTROL SYSTEM 333
PALM COMMAND CONTROL SYSTEM DIAGRAM 333
HSS SYSTEM 337
HSS SYSTEM DIAGRAM 337
FUNCTION OF HSS SYSTEM 338
CENTRALIZED PRESSURE PICKUP PORT 340
LAYOUT OF CENTRALIZED PRESSURE PICKUP PORT 340
FUNCTION OF CENTRALIZED PRESSURE PICKUP PORT 340
COMPONENT PARTS OF POWER TRAIN SYSTEM 341
UNIVERSAL JOINT 341
POWER TRAIN MOUNT 342
TORQUE CONVERTER AND PTO 342
LOCKUP CLUTCH ECMV 347
TRANSMISSION 351
TRANSMISSION CONTROL VALVE 363
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 364
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 370
TRANSMISSION LUBRICATION RELIEF VALVE 372
BEVEL GEAR SHAFT, HSS, AND BRAKE 372
BRAKE VALVE 392
FINAL DRIVE 396
SCAVENGING PUMP 399
STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 400
HSS MOTOR 401
ELECTRIC STEERING CONTROL LEVER 406
WORK EQUIPMENT SYSTEM 410
WORK EQUIPMENT CONTROL 410
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 410
FUNCTION OF WORK EQUIPMENT CONTROL 411
LAYOUT OF TILT DOZER, POWER TILT PITCH DOZER AND ANGLE DOZER SERIES 413
LAYOUT OF POWER ANGLE POWER TILT DOZER SERIES 414
LAYOUT OF FIXED MULTI-SHANK RIPPER 415
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 416
SELF-PRESSURE REDUCING VALVE 416
WORK EQUIPMENT LOCK SOLENOID VALVE 422
BLADE PPC VALVE 426
RIPPER PPC VALVE 432
BLADE PITCH SELECTOR SOLENOID VALVE 435
PILOT CIRCUIT ACCUMULATOR 437
ANGLE CONTROL EPC VALVE 438
QUICK DROP VALVE 441
PISTON VALVE 442
UNDERCARRIAGE AND FRAME 445
MAIN FRAME 445
STRUCTURE OF MAIN FRAME 445
SUSPENSION 447
STRUCTURE OF SUSPENSION 447
SPECIFICATIONS OF SUSPENSION 448
FUNCTION OF SUSPENSION 449
TRACK FRAME AND IDLER CUSHION 450
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 450
FUNCTION OF TRACK FRAME AND IDLER CUSHION 452
WORK EQUIPMENT 453
STRUCTURE OF FRONT WORK EQUIPMENT (FOR TILT DOZER AND POWER TILT PITCH DOZER SERIES) 453
STRUCTURE OF FRONT WORK EQUIPMENT (FOR POWER ANGLE POWER TILT DOZER SERIES) 454
STRUCTURE OF FRONT WORK EQUIPMENT (ANGLE DOZER SERIES) 455
STRUCTURE OF FIXED MULTI-SHANK RIPPER 456
CAB AND ITS ATTACHMENTS 457
ROPS CAB 457
STRUCTURE OF ROPS CAB 457
FUNCTION OF ROPS CAB 458
CAB MOUNT 459
STRUCTURE OF CAB MOUNT 459
FUNCTION OF CAB MOUNT 459
20 STANDARD VALUE TABLE 461
CONTENTS 462
ABBREVIATION LIST 463
STANDARD VALUE TABLE FOR ENGINE 469
STANDARD VALUE TABLE FOR ENGINE: D65EX-18 469
STANDARD VALUE TABLE FOR ENGINE: D65PX-18 474
STANDARD VALUE TABLE FOR ENGINE: D65WX-18 479
STANDARD VALUE TABLE FOR MACHINE 484
STANDARD VALUE TABLE FOR MACHINE: D65EX-18 484
STANDARD VALUE TABLE FOR MACHINE: D65PX-18 500
STANDARD VALUE TABLE FOR MACHINE: D65WX-18 516
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 531
STANDARD VALUE TABLE FOR ELECTRICAL 534
STANDARD VALUE TABLE FOR ELECTRICITY 534
30 TESTING AND ADJUSTING 543
CONTENTS 544
ABBREVIATION LIST 547
RELATED INFORMATION ON TESTING AND ADJUSTING 553
TOOLS FOR TESTING AND ADJUSTING 553
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 559
ENGINE AND COOLING SYSTEM 560
TEST ENGINE SPEED 560
METHOD FOR TESTING ENGINE SPEED 560
TEST BOOST PRESSURE 564
METHOD FOR TESTING BOOST PRESSURE 564
TEST EXHAUST GAS TEMPERATURE 566
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 566
TEST EXHAUST GAS COLOR 568
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 568
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 568
TEST AND ADJUST VALVE CLEARANCE 570
METHOD FOR TESTING VALVE CLEARANCE 570
METHOD FOR ADJUSTING VALVE CLEARANCE 571
TEST COMPRESSION PRESSURE 573
METHOD FOR TESTING COMPRESSION PRESSURE 573
TEST BLOWBY PRESSURE 575
METHOD FOR TESTING BLOWBY PRESSURE 575
TEST ENGINE OIL PRESSURE 578
METHOD FOR TESTING ENGINE OIL PRESSURE 578
TEST EGR VALVE AND VGT OIL PRESSURE 579
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 579
TEST FUEL PRESSURE 581
METHOD FOR TESTING FUEL PRESSURE 582
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 588
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 589
BLEED AIR FROM FUEL SYSTEM 593
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 593
TEST FUEL CIRCUIT FOR LEAKAGE 595
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 595
HANDLE CYLINDER CUT-OUT MODE OPERATION 597
HANDLE NO-INJECTION CRANKING OPERATION 598
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 599
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 599
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 599
TEST ALTERNATOR BELT 600
METHOD FOR REMOVING ALTERNATOR BELT 600
TEST AUTOMATIC TENSIONER 601
METHOD FOR TESTING AUTOMATIC TENSIONER 601
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 603
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 603
TEST SCR RELATED FUNCTIONS 604
TEST AdBlue/DEF PUMP RAISED PRESSURE 608
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 611
TEST AdBlue/DEF LINE HEATER RELAY 1 616
TEST AdBlue/DEF LINE HEATER RELAY 2 619
TEST AdBlue/DEF PUMP HEATER RELAY 622
TEST AdBlue/DEF TANK HEATER VALVE 625
TEST DENITRATION EFFICIENCY OF SCR 628
CLEAN AdBlue/DEF TANK 631
METHOD FOR CLEANING AdBlue/DEF TANK 631
CLEAN AdBlue/DEF TANK MOUNTING PORTION 635
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 635
ADJUST DECELERATOR PEDAL 637
METHOD FOR ADJUSTING DECELERATOR PEDAL 637
POWER TRAIN 639
TEST POWER TRAIN OIL PRESSURE 639
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 640
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 651
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 651
TEST BRAKE PERFORMANCE SIMPLY 653
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 653
ADJUST BRAKE PEDAL 654
METHOD FOR ADJUSTING BRAKE PEDAL 654
ADJUST PARKING BRAKE LEVER 656
METHOD FOR ADJUSTING PARKING BRAKE LEVER 656
MOVE MACHINE BY RELEASING PARKING BRAKE WHEN MACHINE DOES NOT TRAVEL 658
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 658
METHOD FOR MOVING MACHINE WITH ELECTRIC TYPE PARKING BRAKE RELEASE SYSTEM 659
UNDERCARRIAGE AND FRAME 661
ADJUST IDLER CLEARANCE 661
METHOD FOR ADJUSTING IDLER CLEARANCE 661
TEST AND ADJUST TRACK TENSION 662
METHOD FOR TESTING TRACK TENSION 662
METHOD FOR ADJUSTING TRACK TENSION 662
HYDRAULIC SYSTEM 663
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 663
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 663
TEST AND ADJUST WORK EQUIPMENT AND HSS OIL PRESSURES 664
METHOD FOR TESTING WORK EQUIPMENT AND HSS OIL PRESSURES 664
METHOD FOR ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURES 667
TEST OIL PRESSURE OF CONTROL CIRCUIT 668
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 668
TEST PPC VALVE OUTLET PRESSURE 670
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE 670
BLEED AIR FROM HSS PUMP 672
METHOD FOR BLEEDING AIR FROM HSS PUMP 672
TEST AND ADJUST PLAY OF WORK EQUIPMENT PPC VALVE 673
METHOD FOR TESTING PLAY OF WORK EQUIPMENT PPC VALVE 673
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 674
TEST COOLING FAN SPEED 675
METHOD FOR TESTING COOLING FAN SPEED 675
TEST COOLING FAN CIRCUIT OIL PRESSURE 676
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 676
BLEED AIR FROM COOLING FAN PUMP 678
METHOD FOR BLEEDING AIR FROM COOLING FAN PUMP 678
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 679
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 679
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 679
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 680
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 681
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 681
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 683
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 683
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@CENS] 1066
FAILURE CODE [B@HANS] 1067
FAILURE CODE [CA115] 1068
FAILURE CODE [CA122] 1069
FAILURE CODE [CA123] 1071
FAILURE CODE [CA131] 1073
FAILURE CODE [CA132] 1075
FAILURE CODE [CA144] 1078
FAILURE CODE [CA145] 1080
FAILURE CODE [CA153] 1082
FAILURE CODE [CA154] 1085
FAILURE CODE [CA187] 1088
FAILURE CODE [CA221] 1090
FAILURE CODE [CA222] 1092
FAILURE CODE [CA227] 1094
FAILURE CODE [CA234] 1095
FAILURE CODE [CA238] 1096
FAILURE CODE [CA239] 1098
FAILURE CODE [CA249] 1100
FAILURE CODE [CA256] 1102
FAILURE CODE [CA271] 1104
FAILURE CODE [CA272] 1106
FAILURE CODE [CA281] 1108
FAILURE CODE [CA322] 1109
FAILURE CODE [CA323] 1111
FAILURE CODE [CA324] 1113
FAILURE CODE [CA325] 1115
FAILURE CODE [CA331] 1117
FAILURE CODE [CA332] 1119
FAILURE CODE [CA343] 1121
FAILURE CODE [CA351] 1122
FAILURE CODE [CA352] 1123
FAILURE CODE [CA356] 1126
FAILURE CODE [CA357] 1128
FAILURE CODE [CA386] 1130
FAILURE CODE [CA428] 1131
FAILURE CODE [CA429] 1133
FAILURE CODE [CA435] 1135
FAILURE CODE [CA441] 1137
FAILURE CODE [CA442] 1139
FAILURE CODE [CA449] 1140
FAILURE CODE [CA451] 1144
FAILURE CODE [CA452] 1147
FAILURE CODE [CA488] 1149
FAILURE CODE [CA515] 1150
FAILURE CODE [CA516] 1152
FAILURE CODE [CA553] 1154
FAILURE CODE [CA555] 1155
FAILURE CODE [CA556] 1156
FAILURE CODE [CA559] 1157
FAILURE CODE [CA595] 1161
FAILURE CODE [CA687] 1162
FAILURE CODE [CA689] 1164
FAILURE CODE [CA691] 1169
FAILURE CODE [CA692] 1171
FAILURE CODE [CA697] 1173
FAILURE CODE [CA698] 1174
FAILURE CODE [CA731] 1175
FAILURE CODE [CA778] 1177
FAILURE CODE [CA1117] 1182
FAILURE CODE [CA1664] 1183
FAILURE CODE [CA1669] 1186
FAILURE CODE [CA1673] 1187
FAILURE CODE [CA1677] 1188
FAILURE CODE [CA1678] 1189
FAILURE CODE [CA1682] 1190
FAILURE CODE [CA1683] 1195
FAILURE CODE [CA1684] 1197
FAILURE CODE [CA1686] 1199
FAILURE CODE [CA1691] 1200
FAILURE CODE [CA1694] 1203
FAILURE CODE [CA1695] 1206
FAILURE CODE [CA1696] 1207
FAILURE CODE [CA1712] 1209
FAILURE CODE [CA1713] 1212
FAILURE CODE [CA1714] 1214
FAILURE CODE [CA1715] 1215
FAILURE CODE [CA1776] 1216
FAILURE CODE [CA1777] 1219
FAILURE CODE [CA1843] 1222
FAILURE CODE [CA1844] 1224
FAILURE CODE [CA1879] 1227
FAILURE CODE [CA1881] 1230
FAILURE CODE [CA1883] 1233
FAILURE CODE [CA1885] 1237
FAILURE CODE [CA1887] 1239
FAILURE CODE [CA1921] 1241
FAILURE CODE [CA1922] 1244
FAILURE CODE [CA1942] 1249
FAILURE CODE [CA1993] 1250
FAILURE CODE [CA2185] 1253
FAILURE CODE [CA2186] 1255
FAILURE CODE [CA2249] 1257
FAILURE CODE [CA2265] 1258
FAILURE CODE [CA2266] 1260
FAILURE CODE [CA2271] 1262
FAILURE CODE [CA2272] 1265
FAILURE CODE [CA2288] 1268
FAILURE CODE [CA2311] 1269
FAILURE CODE [CA2349] 1270
FAILURE CODE [CA2353] 1273
FAILURE CODE [CA2357] 1275
FAILURE CODE [CA2381] 1276
FAILURE CODE [CA2382] 1279
FAILURE CODE [CA2383] 1282
FAILURE CODE [CA2386] 1285
FAILURE CODE [CA2387] 1287
FAILURE CODE [CA2555] 1288
FAILURE CODE [CA2556] 1291
FAILURE CODE [CA2637] 1294
FAILURE CODE [CA2639] 1296
FAILURE CODE [CA2771] 1299
FAILURE CODE [CA2777] 1305
FAILURE CODE [CA2976] 1308
FAILURE CODE [CA3133] 1310
FAILURE CODE [CA3134] 1312
FAILURE CODE [CA3135] 1314
FAILURE CODE [CA3142] 1318
FAILURE CODE [CA3143] 1319
FAILURE CODE [CA3144] 1320
FAILURE CODE [CA3146] 1322
FAILURE CODE [CA3147] 1323
FAILURE CODE [CA3148] 1324
FAILURE CODE [CA3151] 1326
FAILURE CODE [CA3165] 1332
FAILURE CODE [CA3229] 1334
FAILURE CODE [CA3231] 1336
FAILURE CODE [CA3232] 1338
FAILURE CODE [CA3235] 1342
FAILURE CODE [CA3239] 1344
FAILURE CODE [CA3241] 1347
FAILURE CODE [CA3242] 1350
FAILURE CODE [CA3251] 1353
FAILURE CODE [CA3253] 1355
FAILURE CODE [CA3254] 1358
FAILURE CODE [CA3255] 1361
FAILURE CODE [CA3256] 1364
FAILURE CODE [CA3311] 1366
FAILURE CODE [CA3312] 1368
FAILURE CODE [CA3313] 1371
FAILURE CODE [CA3314] 1372
FAILURE CODE [CA3315] 1373
FAILURE CODE [CA3316] 1376
FAILURE CODE [CA3317] 1377
FAILURE CODE [CA3318] 1378
FAILURE CODE [CA3319] 1381
FAILURE CODE [CA3321] 1382
FAILURE CODE [CA3322] 1384
FAILURE CODE [CA3419] 1387
FAILURE CODE [CA3421] 1389
FAILURE CODE [CA3497] 1391
FAILURE CODE [CA3498] 1392
FAILURE CODE [CA3543] 1393
FAILURE CODE [CA3545] 1400
FAILURE CODE [CA3547] 1402
FAILURE CODE [CA3558] 1403
FAILURE CODE [CA3559] 1405
FAILURE CODE [CA3562] 1407
FAILURE CODE [CA3563] 1409
FAILURE CODE [CA3567] 1412
FAILURE CODE [CA3568] 1415
FAILURE CODE [CA3571] 1422
FAILURE CODE [CA3572] 1424
FAILURE CODE [CA3574] 1426
FAILURE CODE [CA3575] 1428
FAILURE CODE [CA3577] 1430
FAILURE CODE [CA3578] 1432
FAILURE CODE [CA3582] 1434
FAILURE CODE [CA3583] 1442
FAILURE CODE [CA3596] 1444
FAILURE CODE [CA3649] 1447
FAILURE CODE [CA3681] 1449
FAILURE CODE [CA3682] 1451
FAILURE CODE [CA3713] 1454
FAILURE CODE [CA3717] 1457
FAILURE CODE [CA3718] 1458
FAILURE CODE [CA3725] 1459
FAILURE CODE [CA3741] 1462
FAILURE CODE [CA3748] 1463
FAILURE CODE [CA3751] 1466
FAILURE CODE [CA3755] 1468
FAILURE CODE [CA3866] 1470
FAILURE CODE [CA3867] 1474
FAILURE CODE [CA3868] 1477
FAILURE CODE [CA3899] 1481
FAILURE CODE [CA3911] 1483
FAILURE CODE [CA3912] 1487
FAILURE CODE [CA3932] 1489
FAILURE CODE [CA3933] 1491
FAILURE CODE [CA3934] 1493
FAILURE CODE [CA3935] 1496
FAILURE CODE [CA3936] 1498
FAILURE CODE [CA4151] 1500
FAILURE CODE [CA4152] 1504
FAILURE CODE [CA4155] 1508
FAILURE CODE [CA4156] 1511
FAILURE CODE [CA4157] 1514
FAILURE CODE [CA4158] 1516
FAILURE CODE [CA4159] 1517
FAILURE CODE [CA4161] 1518
FAILURE CODE [CA4162] 1520
FAILURE CODE [CA4163] 1523
FAILURE CODE [CA4164] 1525
FAILURE CODE [CA4165] 1527
FAILURE CODE [CA4166] 1529
FAILURE CODE [CA4168] 1531
FAILURE CODE [CA4169] 1534
FAILURE CODE [CA4171] 1536
FAILURE CODE [CA4249] 1539
FAILURE CODE [CA4251] 1541
FAILURE CODE [CA4259] 1543
FAILURE CODE [CA4261] 1546
FAILURE CODE [CA4277] 1549
FAILURE CODE [CA4281] 1553
FAILURE CODE [CA4459] 1557
FAILURE CODE [CA4461] 1560
FAILURE CODE [CA4658] 1563
FAILURE CODE [CA4731] 1567
FAILURE CODE [CA4732] 1568
FAILURE CODE [CA4739] 1569
FAILURE CODE [CA4768] 1570
FAILURE CODE [CA4769] 1572
FAILURE CODE [CA4842] 1575
FAILURE CODE [CA4952] 1579
FAILURE CODE [CA5115] 1581
FAILURE CODE [CA5383] 1584
FAILURE CODE [D130KA] 1586
FAILURE CODE [D130KB] 1589
FAILURE CODE [D19DKA] 1591
FAILURE CODE [D19DKB] 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 1995
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2001
HOW TO READ THIS MANUAL 2001
COATING MATERIALS LIST 2003
SPECIAL TOOLS LIST 2007
SKETCHES OF SPECIAL TOOLS 2029
ENGINE AND COOLING SYSTEM 2050
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2050
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2050
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2054
REMOVE AND INSTALL INJECTOR ASSEMBLY 2059
METHOD FOR REMOVING INJECTOR ASSEMBLY 2060
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2067
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2078
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2079
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2089
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2105
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2105
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2106
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2107
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2107
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2108
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2110
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2110
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2112
REMOVE AND INSTALL ALTERNATOR BELT 2114
METHOD FOR REMOVING ALTERNATOR BELT 2114
METHOD FOR INSTALLING ALTERNATOR BELT 2115
REMOVE AND INSTALL AUTOMATIC TENSIONER 2117
METHOD FOR REMOVING AUTOMATIC TENSIONER 2117
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2117
REMOVE AND INSTALL RADIATOR ASSEMBLY 2118
METHOD FOR REMOVING RADIATOR ASSEMBLY 2118
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2121
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2125
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2125
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2127
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2130
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2130
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2132
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY 2135
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2135
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2137
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2140
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY 2140
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY 2141
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2143
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY 2143
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY 2145
REMOVE AND INSTALL ENGINE ASSEMBLY 2147
METHOD FOR REMOVING ENGINE ASSEMBLY 2147
METHOD FOR INSTALLING ENGINE ASSEMBLY 2151
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2157
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2157
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2159
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2163
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2163
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2167
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2175
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2175
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2178
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2181
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2181
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2183
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2185
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2186
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2190
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2194
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2195
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2200
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2206
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2206
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2207
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2214
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2214
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2214
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2215
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2215
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2216
REMOVE AND INSTALL KDPF ASSEMBLY 2219
METHOD FOR REMOVING KDPF ASSEMBLY 2219
METHOD FOR INSTALLING KDPF ASSEMBLY 2223
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2227
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2227
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2231
REMOVE AND INSTALL SCR ASSEMBLY 2237
METHOD FOR REMOVING SCR ASSEMBLY 2237
METHOD FOR INSTALLING SCR ASSEMBLY 2239
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2242
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2242
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2249
REMOVE AND INSTALL KCCV ASSEMBLY 2256
METHOD FOR REMOVING KCCV ASSEMBLY 2256
METHOD FOR INSTALLING KCCV ASSEMBLY 2258
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2260
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2260
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2263
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2268
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2268
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2271
REMOVE AND INSTALL AdBlue/DEF PUMP 2275
METHOD FOR REMOVING AdBlue/DEF PUMP 2275
METHOD FOR INSTALLING AdBlue/DEF PUMP 2278
REMOVE AND INSTALL AdBlue/DEF HOSE 2281
METHOD FOR REMOVING AdBlue/DEF HOSE 2281
METHOD FOR INSTALLING AdBlue/DEF HOSE 2286
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2291
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2291
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2292
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2294
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2294
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2296
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2299
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2299
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2301
POWER TRAIN 2303
REMOVE AND INSTALL DAMPER ASSEMBLY 2303
METHOD FOR REMOVING DAMPER ASSEMBLY 2303
METHOD FOR INSTALLING DAMPER ASSEMBLY 2306
REMOVE AND INSTALL POWER TRAIN UNIT ASSEMBLY 2311
METHOD FOR REMOVING POWER TRAIN UNIT ASSEMBLY 2311
METHOD FOR INSTALLING POWER TRAIN UNIT ASSEMBLY 2316
DISCONNECTING AND CONNECTING POWER TRAIN UNIT ASSEMBLY 2322
METHOD FOR DISCONNECTING POWER TRAIN UNIT ASSEMBLY 2322
METHOD FOR CONNECTING POWER TRAIN UNIT ASSEMBLY 2327
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY 2333
METHOD FOR DISASSEMBLING PTO ASSEMBLY 2333
METHOD FOR ASSEMBLING PTO ASSEMBLY 2336
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2340
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2341
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2347
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2356
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2357
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY 2375
DISASSEMBLE AND ASSEMBLE HSS ASSEMBLY 2388
METHOD FOR DISASSEMBLING HSS ASSEMBLY 2390
METHOD FOR ASSEMBLING HSS ASSEMBLY 2401
REMOVAL AND INSTALLATION OF HSS MOTOR 2418
METHOD FOR REMOVING HSS MOTOR ASSEMBLY 2418
METHOD FOR INSTALLING HSS MOTOR ASSEMBLY 2420
REMOVE AND INSTALL FINAL DRIVE ASSEMBLY 2423
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2423
METHOD FOR INSTALLING FINAL DRIVE ASSEMBLY 2425
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2428
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2430
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2437
UNDERCARRIAGE AND FRAME 2447
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2447
METHOD FOR REMOVING TRACK FRAME ASSEMBLY 2447
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY 2449
REMOVE AND INSTALL IDLER ASSEMBLY 2452
METHOD FOR REMOVING IDLER ASSEMBLY 2452
METHOD FOR INSTALLING IDLER ASSEMBLY 2453
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2455
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2455
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2457
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2461
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY 2461
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY 2461
DISASSEMBLE AND ASSEMBLE RECOIL SPRING 2463
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING 2463
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY 2466
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 2469
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2469
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2469
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2471
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2471
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2473
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 2476
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2476
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2477
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2478
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2478
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2479
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2482
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY 2482
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY 2483
SEPARATE AND CONNECT TRACK ASSEMBLY 2484
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY 2484
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2484
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2485
METHOD FOR CONNECTING TRACK ASSEMBLY 2486
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2488
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY 2488
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY 2488
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2489
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2489
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY 2492
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2504
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2505
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2506
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2521
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2522
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2523
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2530
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2531
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2533
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2537
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 2537
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 2538
DISASSEMBLE AND ASSEMBLE EQUALIZER BAR BUSHINGS 2540
METHOD FOR DISASSEMBLING EQUALIZER BAR BUSHINGS 2540
METHOD FOR ASSEMBLING EQUALIZER BAR BUSHINGS 2540
HYDRAULIC SYSTEM 2542
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2542
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2542
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2545
REMOVE AND INSTALL HSS PUMP AND COOLING FAN PUMP ASSEMBLY 2550
METHOD FOR REMOVING HSS PUMP AND COOLING FAN PUMP ASSEMBLY 2550
METHOD FOR INSTALLING HSS PUMP AND COOLING FAN PUMP ASSEMBLY 2551
REMOVE AND INSTALL POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2554
METHOD FOR REMOVING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2554
METHOD FOR INSTALLING POWER TRAIN PUMP AND STEERING LUBRICATION PUMP ASSEMBLY 2556
REMOVE AND INSTALL SCAVENGING PUMP ASSEMBLY 2559
METHOD FOR REMOVING SCAVENGING PUMP ASSEMBLY 2559
METHOD FOR INSTALLING SCAVENGING PUMP ASSEMBLY 2559
REMOVE AND INSTALL 5 SPOOL CONTROL VALVE ASSEMBLY 2561
METHOD FOR REMOVING 5 SPOOL CONTROL VALVE ASSEMBLY 2561
METHOD FOR INSTALLING 5 SPOOL CONTROL VALVE ASSEMBLY 2563
REMOVE AND INSTALL 4 SPOOL CONTROL VALVE ASSEMBLY 2566
METHOD FOR REMOVING 4 SPOOL CONTROL VALVE ASSEMBLY 2566
METHOD FOR INSTALLING 4 SPOOL CONTROL VALVE ASSEMBLY 2568
DISASSEMBLE AND ASSEMBLE BLADE PPC VALVE 2572
METHOD FOR DISASSEMBLING BLADE PPC VALVE 2572
METHOD FOR ASSEMBLING BLADE PPC VALVE 2572
DISASSEMBLE AND ASSEMBLE RIPPER PPC VALVE 2574
METHOD FOR DISASSEMBLING RIPPER PPC VALVE 2574
METHOD FOR ASSEMBLING RIPPER PPC VALVE 2574
WORK EQUIPMENT 2576
REMOVE AND INSTALL STRAIGHT TILT POWER PITCH DOZER BLADE ASSEMBLY 2576
METHOD FOR REMOVING STRAIGHT TILT POWER PITCH DOZER BLADE ASSEMBLY 2576
METHOD FOR INSTALLING STRAIGHT TILT POWER PITCH DOZER BLADE ASSEMBLY 2578
REMOVE AND INSTALL POWER ANGLE POWER TILT DOZER BLADE ASSEMBLY 2582
METHOD FOR REMOVING POWER ANGLE POWER TILT DOZER BLADE ASSEMBLY 2582
METHOD FOR INSTALLING POWER ANGLE POWER TILT DOZER BLADE ASSEMBLY 2584
REMOVE AND INSTALL RIPPER ASSEMBLY 2587
METHOD FOR REMOVING RIPPER ASSEMBLY 2587
METHOD FOR INSTALLING RIPPER ASSEMBLY 2590
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2593
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2594
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2597
CAB AND ITS ATTACHMENTS 2601
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2601
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2601
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2608
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2617
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 2617
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 2618
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2623
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2623
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2628
REMOVE AND INSTALL OPERATOR’S SEAT 2634
METHOD FOR REMOVING OPERATOR’S SEAT 2634
METHOD FOR INSTALLING OPERATOR’S SEAT 2636
REMOVE AND INSTALL SEAT BELT 2638
METHOD FOR REMOVING SEAT BELT 2638
METHOD FOR INSTALLING SEAT BELT 2639
ELECTRICAL SYSTEM 2640
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2640
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2640
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2641
REMOVE AND INSTALL POWER TRAIN CONTROLLER ASSEMBLY 2644
METHOD FOR REMOVING POWER TRAIN CONTROLLER ASSEMBLY 2644
METHOD FOR INSTALLING POWER TRAIN CONTROLLER ASSEMBLY 2645
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2647
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2647
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2648
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2650
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2650
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2651
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2652
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2652
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2652
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2654
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2654
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2656
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2658
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2658
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2660
60 MAINTENANCE STANDARD 2663
CONTENTS 2664
ABBREVIATION LIST 2666
ENGINE AND COOLING SYSTEM 2672
MAINTENANCE STANDARD OF ENGINE MOUNT 2672
MAINTENANCE STANDARD OF DAMPER 2673
MAINTENANCE STANDARD OF COOLING SYSTEM 2675
MAINTENANCE STANDARD OF COOLING FAN PUMP 2677
MAINTENANCE STANDARD OF SERVO VALVE 2678
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2679
POWER TRAIN 2681
MAINTENANCE STANDARD OF UNIVERSAL JOINT 2681
MAINTENANCE STANDARD OF POWER TRAIN MOUNT 2682
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 2684
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 2687
MAINTENANCE STANDARD OF TRANSMISSION 2688
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 2693
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 2694
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 2695
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE 2696
MAINTENANCE STANDARD OF BEVEL GEAR SHAFT, HSS, AND BRAKE 2697
MAINTENANCE STANDARD OF BRAKE VALVE 2702
MAINTENANCE STANDARD OF FINAL DRIVE 2704
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 2707
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE 2708
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2710
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE 2711
UNDERCARRIAGE AND FRAME 2713
MAINTENANCE STANDARD OF MAIN FRAME 2713
MAINTENANCE STANDARD OF SUSPENSION 2714
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2716
MAINTENANCE STANDARD OF IDLER 2718
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2720
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2721
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2722
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2723
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE 2724
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2725
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 2726
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 2728
MAINTENANCE STANDARD OF SINGLE SHOE 2730
MAINTENANCE STANDARD OF SWAMP SHOE 2731
HYDRAULIC SYSTEM 2732
MAINTENANCE STANDARD OF HYDRAULIC TANK 2732
MAINTENANCE STANDARD OF SCAVENGING PUMP 2733
MAINTENANCE STANDARD OF STEERING LUBRICATION PUMP AND POWER TRAIN PUMP 2734
MAINTENANCE STANDARD OF WORK EQUIPMENT AND HSS PUMP 2735
MAINTENANCE STANDARD OF PC-EPC VALVE 2736
MAINTENANCE STANDARD OF HSS MOTOR 2737
MAINTENANCE STANDARD OF CONTROL VALVE 2739
MAINTENANCE STANDARD OF BLADE PPC VALVE 2747
MAINTENANCE STANDARD OF RIPPER PPC VALVE 2749
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE 2751
MAINTENANCE STANDARD OF QUICK DROP VALVE 2752
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE (FOR TILT DOZER AND ANGLE DOZER SERIES) 2754
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE (FOR POWER TILT PITCH DOZER SERIES) 2755
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE (FOR POWER ANGLE POWER TILT DOZER SERIES) 2756
WORK EQUIPMENT 2757
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT (FOR TILT DOZER AND POWER TILT PITCH DOZER SERIES) 2757
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT (FOR POWER ANGLE POWER TILT DOZER SERIES) 2760
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT (ANGLE DOZER SERIES) 2763
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 2766
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER (FOR TILT DOZER AND POWER TILT PITCH DOZER, AND ANGLE DOZER SERIES) 2768
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER (FOR POWER ANGLE POWER TILT DOZER SERIES) 2769
MAINTENANCE STANDARD OF BLADE TILT CYLINDER (FOR TILT DOZER AND POWER TILT PITCH DOZER, AND ANGLE DOZER SERIES) 2770
MAINTENANCE STANDARD OF BLADE TILT CYLINDER (FOR POWER ANGLE POWER TILT DOZER SERIES) 2771
MAINTENANCE STANDARD OF BLADE PITCH CYLINDER (FOR POWER TILT PITCH DOZER SERIES) 2772
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER (FOR POWER ANGLE POWER TILT DOZER SERIES) 2773
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 2774
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 2775
CAB AND ITS ATTACHMENTS 2776
MAINTENANCE STANDARD OF CAB MOUNT 2776
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

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