Komatsu Bulldozer D65EX-18E0,D65PX-18E0,D65WX-18E0 Shop Manual SEN06756-06 PDF

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Komatsu Bulldozer D65EX-18E0,D65PX-18E0,D65WX-18E0 Shop Manual SEN06756-06 – PDF DOWNLOAD

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Komatsu Bulldozer  D65EX-18E0,D65PX-18E0,D65WX-18E0 Shop Manual SEN06756-06 – PDF DOWNLOAD

Language : English
Pages : 3118
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer  D65EX-18E0,D65PX-18E0,D65WX-18E0 Shop Manual SEN06756-06 – PDF DOWNLOAD

• SERIAL NUMBERS
  D65EX- 91845          and up
  D65PX- 91845          and up
  D65WX-91845          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
Procedures If Fire Occurs . 40
Precautions When You Discard Waste Materials 41
Procedures for Exhaust Gas Regulations 42
Precautions for DEF . 43
General Character and Precautions for Handling 43
Precautions When You Add 43
Precautions for Storage . 43
Precautions for Fire Hazard and Leakage . 43
Other Precautions . 43
Store DEF . 44
Precautions When You Handle Hydraulic Equipment . 45
Precautions When You Disconnect and Connect Pipings . 48
Precautions When You Handle Electrical Equipment 55
Precautions When You Handle Fuel System Equipment . 57
Precautions When You Handle Intake System Equipment . 58
Practical Use of KOMTRAX 59
Disconnect and Connect Push-Pull Type Coupler . 60
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 60
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 61
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 62
Precautions for Disconnection and Connection of Connectors 64
Disconnect and Connect Deutsch Connector 68
How to Disconnect and Connect Slide Lock Type Connector . 69
Disconnect and Connect Connector with Lock to Pull 71
Disconnect and Connect Connector with Lock to Push 72
Disconnect and Connect Connector with Housing to Rotate . 74
How to Read the Codes for Electric Cable 75
Explanation of Terms for Maintenance Standard . 79
Standard Tightening Torque Table 82
Conversion Table 89
01 Specification 95
Table of Contents . 96
Abbreviation List . 97
Specifications 103
Specification Drawing . 103
Specification Drawing: D65EX-18E0 . 103
Specification Drawing: D65PX-18E0 . 104
Specification Drawing: D65PX-18E0 (Wide Gauge Specification) 105
Specification Drawing: D65WX-18E0 . 106
Specifications 108
Specifications: D65EX-18E0 108
Specifications: D65PX-18E0 116
Specifications: D65PX-18E0 (Wide Gauge Specification) . 122
Specifications: D65WX-18E0 126
Weight Table 134
Weight Table: D65EX-18E0 134
Weight Table: D65PX-18E0 137
Weight Table: D65PX-18E0 (Wide Gauge Specification) . 140
Weight Table: D65WX-18E0 142
Table of Fuel, Coolant, and Lubricants 146
10 Structure and Function . 149
Table of Contents . 150
Abbreviation List . 153
Urea SCR System . 159
Layout Drawing of Urea SCR System . 159
Urea SCR System Diagram . 161
Function of Urea SCR System . 162
Function of DEF System 162
Inducement Strategy . 164
Component Parts of Urea SCR System 178
DEF Mixing Tube . 178
SCR Assembly 178
DEF Tank 181
DEF Pump 183
DEF Injector 184
DEF Hose 185
DEF Tank Heating Valve 186
Boot-up System 187
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 187
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) . 189
System Operating Lamp System 191
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 191
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) . 191
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 191
Function of System Operating Lamp System (Machine with Gateway Function Controller) . 192
Battery Disconnect Switch . 194
Layout Drawing of Battery Disconnect Switch . 194
Function of Battery Disconnect Switch . 194
Engine System . 196
Layout Drawing of Engine System . 196
Engine Control System . 198
Layout of Engine Control System (Machine with KOMTRAX Terminal) . 198
Layout of Engine Control System (Machine with Gateway Function Controller) 200
System Diagram of Engine Control System (Machine with KOMTRAX Terminal) . 201
System Diagram of Engine Control System (Machine with Gateway Function Controller) 203
Function of Engine Control System (Machine with KOMTRAX Terminal) . 205
Function of Engine Control System (Machine with Gateway Function Controller) 207
Automatic Idle Stop System 209
Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal) 209
System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller) . 210
Function of Automatic Idle Stop System 210
Component Parts of Engine System 213
Damper 213
VGT . 214
EGR System 218
EGR Valve . 220
EGR Cooler 222
KCCV System . 223
KCCV Ventilator . 225
KDPF 227
Cooling System 232
Layout Drawing of Cooling System 232
Specifications of Cooling System 233
Cooling Fan Control System 234
System Diagram of Cooling Fan Control System 234
Function of Cooling Fan Control System 235
Component Parts of Cooling System . 237
Cooling Fan Pump 237
Cooling Fan Motor . 246
Hydraulic Oil Cooler Bypass Valve . 253
Control System 254
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 254
Layout Drawing of Control System (Machine with Gateway Function Controller) . 255
Machine Monitor System 256
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 256
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) . 257
Function of Machine Monitor System 257
KOMTRAX System 258
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 258
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) . 258
Function of KOMTRAX System 259
Component Parts of Control System . 260
Machine Monitor . 260
KOMTRAX Terminal 275
Gateway Function Controller . 277
Communication Terminal 280
Power Train Controller 282
Engine Controller . 286
Hydraulic System 293
Layout Drawing of Hydraulic System 293
CLSS 294
Structure of CLSS . 294
Function of CLSS 295
Component Parts of Hydraulic System . 297
Hydraulic Tank 297
Work Equipment and HSS Pump . 298
LS Valve 303
PC Valve 308
PC-EPC Valve 313
Control Valve . 317
Power Train System 348
Layout Drawing of Power Train System 348
Operation of Power Train System . 351
Transmission, Steering, and Brake Control . 352
Layout Drawing of Transmission, Steering, and Brake Control System 352
Function of Transmission, Steering, and Brake Control . 353
Palm Command Control System . 354
Palm Command Control System Diagram . 354
HSS System 358
HSS System Diagram 358
Function of HSS System 359
Centralized Pressure Pickup Port 361
Layout Drawing of Centralized Pressure Pickup Port 361
Function of Centralized Pressure Pickup Port 361
Component Parts of Power Train System . 362
Universal Joint . 362
Power Train Mount . 363
Torque Converter and PTO 364
Lockup Clutch ECMV 369
Transmission 373
Transmission Control Valve 385
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 386
Main Relief Valve and Torque Converter Relief Valve . 391
Transmission Lubrication Relief Valve . 393
Bevel Gear Shaft, HSS, and Brake 394
Brake Valve . 413
Final Drive . 417
Scavenging Pump . 420
Steering Lubrication Pump and Power Train Pump 421
HSS Motor . 422
Electric Steering Electric Lever 427
Work Equipment System . 431
Work Equipment Control 431
Layout Drawing of Work Equipment Control 431
Function of Work Equipment Control 432
Layout Drawing of Tilt Dozer, Power Tilt Pitch Dozer, Angle Dozer and Semi-U Dozer Series . 434
Layout of Power Angle Power Tilt Dozer Series . 436
Layout Drawing of Fixed Multi-Shank Ripper 437
Component Parts of Work Equipment System 438
Self-Pressure Reducing Valve 438
Work Equipment Lock Solenoid Valve 444
Blade PPC Valve . 448
Ripper PPC Valve 454
Blade Pitch Selector Solenoid Valve . 457
Pilot Circuit Accumulator . 459
Angle Control EPC Valve . 460
Quick Drop Valve 463
Piston Valve 464
Undercarriage and Frame . 467
Main Frame 467
Structure of Main Frame . 467
Suspension 469
Structure of Suspension . 469
Specifications of Suspension 470
Function of Suspension 471
Track Frame and Idler Cushion . 472
Structure of Track Frame and Idler Cushion 472
Function of Track Frame and Idler Cushion . 474
Work Equipment 475
Structure of Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series) 475
Structure of Front Work Equipment (For Power Angle Power Tilt Dozer Series) . 476
Structure of Front Work Equipment (Angle Dozer Series) 477
Structure of Fixed Multi-Shank Ripper . 478
CAB Related Parts . 479
ROPS CAB 479
Structure of ROPS CAB (Machine with KOMTRAX Terminal) . 479
Structure of ROPS CAB (Machine with Gateway Function Controller) 480
Function of ROPS CAB 481
CAB Mount . 482
Structure of CAB Mount 482
Function of CAB Mount . 482
20 Standard Value Table . 483
Table of Contents . 484
Abbreviation List . 485
Standard Value Table for Engine . 491
Standard Value Table for Engine: D65EX-18E0 . 491
Standard Value Table for Engine: D65PX-18E0 . 496
Standard Value Table for Engine: D65WX-18E0 . 501
Standard Value Table for Machine 506
Standard Value Table for Machine: D65EX-18E0 506
Standard Value Table for Machine: D65PX-18E0 521
Standard Value Table for Machine: D65WX-18E0 536
Machine Posture and Procedures to Measure Performance . 551
Standard Value Table for Electricity 553
Standard Value Table for Electricity 553
30 Testing and Adjusting 563
Table of Contents . 564
Precautions Before Work . 567
Abbreviation List . 568
Related Information on Testing and Adjusting 574
Tools for Testing and Adjusting . 574
Sketch of Tools for Testing and Adjusting . 580
Engine and Cooling System . 581
Examine Engine Speed 581
How to Examine Engine Speed . 581
Examine Boost Pressure 585
How to Examine Boost Pressure . 585
Examine Exhaust Gas Temperature . 587
How to Examine Exhaust Gas Temperature 587
Examine Exhaust Gas Color . 589
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 589
How to Examine Exhaust Gas Color with Smoke Meter . 589
Examine Mass Air Flow and Temperature Sensor 591
How to Examine Mass Air Flow and Temperature Sensor . 591
Examine and Adjust Valve Clearance 593
Check Valve Clearance . 593
Adjust Valve Clearance 594
Examine Compression Pressure 596
How to Examine Compression Pressure . 596
Examine Blowby Pressure . 598
How to Examine Blowby Pressure 598
Examine Engine Oil Pressure . 601
How to Examine Engine Oil Pressure 601
Examine EGR Valve and VGT Oil Pressure 602
How to Examine EGR Valve and VGT Oil Pressure . 602
Examine Fuel Pressure . 604
How to Examine Fuel Pressure 605
Examine Fuel Discharge, Return and Leakage 611
How to Examine Fuel Discharge, Return, and Leakage 612
Bleed Air from Fuel System 616
How to Bleed Air from Fuel System . 616
Examine Fuel Circuit for Leakage 618
How to Examine Fuel System for Leakage 618
Handle Cylinder Cut-out Mode Operation 620
Handle No-Injection Cranking Operation 621
Examine and Adjust Air Conditioner Compressor Belt Tension 622
How to Examine Air Conditioner Compressor Belt Tension 622
How to Adjust Air Conditioner Compressor Belt Tension . 622
Examine Alternator Belt . 623
How to Examine Alternator Belt 623
Examine Automatic Tensioner . 625
How to Examine Automatic Tensioner 625
Write Correction for Ash in Soot Accumulation to Engine Controller 627
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 627
Examine SCR Related Functions . 628
Examine DEF Pump Raised Pressure 631
Examine Injection Volume from DEF Injector 633
Examine DEF Line Heater Relay 1 . 638
Examine DEF Line Heater Relay 2 . 640
Examine DEF Pump Heater Relay . 643
Examine DEF Tank Heater Valve . 646
Examine SCR Denitration Efficiency 648
Clean DEF Tank 652
How to Clean DEF Tank . 652
Clean DEF Tank Mounting Part 656
How to Clean DEF Tank Mounting Part . 656
Clean DEF Pump 658
How to Clean DEF Pump . 658
Adjust Decelerator Pedal 664
How to Adjust Decelerator Pedal . 664
Power Train . 666
Examine Power Train Oil Pressure 666
How to Examine Power Train Oil Pressure . 667
Adjust Transmission Output Shaft Speed Sensor . 678
How to Adjust Transmission Output Shaft Speed Sensor 678
Examine Brake Performance Simply 680
How to Examine Brake Performance Simply . 680
Adjust Brake Pedal 681
How to Adjust Brake Pedal . 681
Adjust Parking Brake Lever 683
How to Adjust Parking Brake Lever . 683
Move Machine by Parking Brake Release When Machine Does Not Travel 685
Move Machine with Hydraulic Type Parking Brake Release System . 685
Move Machine with Electric Type Parking Brake Release System 686
Undercarriage and Frame . 688
Adjust Idler Clearance 688
How to Adjust Idler Clearance . 688
Examine and Adjust Track Tension 689
How to Examine Track Tension 689
How to Adjust Track Tension . 689
Hydraulic System 690
Release Remained Pressure in Hydraulic Circuit 690
How to Release Remained Pressure in Hydraulic System 690
Examine and Adjust Work Equipment and HSS Oil Pressure 691
How to Examine Work Equipment and HSS Oil Pressure 691
Adjust Oil Pressure of Work Equipment and HSS . 695
Examine Oil Pressure of Control Circuit . 696
Examine Oil Pressure in Control Circuit . 696
Examine PPC Valve Outlet Pressure . 698
Examine Outlet Pressure in PPC Valve 698
Bleed Air from HSS Pump . 700
How to Bleed Air from HSS Pump 700
Examine and Adjust Play of Work Equipment PPC Valve . 701
How to Examine Play of Work Equipment PPC Valve . 701
How to Adjust Play of Work Equipment PPC Valve 702
Examine Cooling Fan Speed . 703
How to Examine Cooling Fan Speed 703
Examine Cooling Fan Circuit Oil Pressure 704
How to Examine Cooling Fan Circuit Oil Pressure . 704
Bleed Air in Cooling Fan Pump . 706
How to Bleed Air in Cooling Fan Pump 706
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 707
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder . 707
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder . 707
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 708
Examine Oil Leakage from Work Equipment Cylinder 709
How to Examine Internal Oil Leakage of Work Equipment Cylinder 709
Bleed Air from Work Equipment Cylinders . 711
Bleed Air from Work Equipment Cylinder 711
Work Equipment 713
Adjust Work Equipment Lock Lever 713
How to Adjust Work Equipment Lock Lever . 713
CAB Related Parts . 715
Examine and Adjust Operator Cab . 715
Examine Operator Cab 715
Adjust Operator Cab . 717
Electrical System . 720
Set and Operate Machine Monitor . 720
Operator Mode . 723
Function to Show Technician Identification Status Screen 723
Function to Show Operator Identification Input Screen . 723
Examine Function by LCD (Liquid Crystal Display) 724
Examine Function of Service Meter . 725
Usage Limitation and Change Maintenance Password 725
Service Mode 727
How to Operate Service Mode . 727
How to See Pre-defined Monitoring Information . 729
How to Examine Self-Define Monitor Information 735
Abnormality Record Menu . 744
How to See Maintenance Record . 749
Maintenance Mode Setting 750
Set Phone Number Entry 753
Default Menu 754
Diagnostic Tests Menu . 761
Adjustment Menu . 770
No-Injection Cranking Operation . 800
KOMTRAX Settings Menu . 801
Show Service Message 806
Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) . 808
Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 813
Start Up KOMTRAX System (Machine with Gateway Function Controller) 815
Stop Use of KOMTRAX System (Machine with Gateway Function Controller) . 821
Adjust When Power Train Controller is Replaced 823
How to Adjust When Power Train Controller is Replaced . 823
Adjust Rearview Camera Angle 826
How to Adjust Rearview Camera Angle . 826
Handle Voltage Circuit of Engine Controller . 827
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 828
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) . 829
Examine Diodes 830
Examine Diodes by Digital Tester 830
How to Examine Diodes by Analog Tester 830
Pm Clinic . 831
Pm Clinic Service . 831
Pm Clinic Check Sheet: D65EX-18E0 . 832
Pm Clinic Check Sheet: D65PX-18E0 . 844
Pm Clinic Check Sheet: D65WX-18E0 . 856
Pm Clinic Check Sheet for Undercarriage: D65EX-18E0 . 868
Pm Clinic Check Sheet for Undercarriage: D65PX-18E0 . 876
Pm Clinic Check Sheet for Undercarriage: D65WX-18E0 . 882
40 Troubleshooting 889
Table of Contents . 890
Precautions Before Work . 900
Abbreviation List . 901
Related Information to Troubleshooting 907
General Troubleshooting Points 907
Troubleshooting Points for Urea SCR System 908
Sequence of Events in Troubleshooting . 920
Checks Before Troubleshooting . 922
Inspection Procedure Before Troubleshooting . 924
Walk-Around Check . 924
Test in Accordance with Testing Procedure . 926
How to Examine Electric Equipment . 926
Preparation for Troubleshooting of Electrical System 934
Procedure for Troubleshooting . 942
Symptom and Troubleshooting Numbers . 945
Information Shown in Troubleshooting Table 948
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 950
Connector List and Layout (Machine with KOMTRAX Terminal) . 952
Connector List and Layout (Machine with Gateway Function Controller) 968
Connector Contact Connection Table 987
T-Branch Box and T-Branch Adapter Table .1027
Fuse Location Table (Machine with KOMTRAX Terminal) .1033
Fuse Location Table (Machine with Gateway Function Controller) 1036
Precautions When You Clean and Replace KDPF (KCSF and KDOC) .1039
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1043
Failure Code Table 1045
Troubleshooting by Failure Code (Display of Code) .1064
Failure Code [1500L0] .1064
Failure Code [15SAL1] .1065
Failure Code [15SALH] .1067
Failure Code [15SBL1] .1069
Failure Code [15SBLH] .1071
Failure Code [15SEL1] .1073
Failure Code [15SELH] .1075
Failure Code [15SFL1] .1077
Failure Code [15SFLH] .1079
Failure Code [15SGL1] .1081
Failure Code [15SGLH] .1083
Failure Code [15SJL1] .1085
Failure Code [15SJLH] .1087
Failure Code [1800MW] .1089
Failure Code [879AKA] .1090
Failure Code [879AKB] .1091
Failure Code [879BKA] .1092
Failure Code [879BKB] .1094
Failure Code [879CKA] .1096
Failure Code [879CKB] .1097
Failure Code [879DKZ] .1098
Failure Code [879EMC] .1100
Failure Code [879FMC] .1101
Failure Code [879GKX] .1102
Failure Code [989L00] .1104
Failure Code [989M00] .1105
Failure Code [989N00] .1106
Failure Code [A1U0N3] .1107
Failure Code [A1U0N4] .1109
Failure Code [A900FR] .1111
Failure Code [A900N6] .1112
Failure Code [A900NY] .1113
Failure Code [AA10NX] .1114
Failure Code [AB00KE] .1116
Failure Code [AQ10N3] .1118
Failure Code [AS00N3] .1120
Failure Code [AS00R2] .1122
Failure Code [AS00R3] .1123
Failure Code [AS00R4] .1124
Failure Code [AS00R5] .1125
Failure Code [AS00R6] .1126
Failure Code [AS00ZK] .1127
Failure Code [AS10KM] .1128
Failure Code [AS10NR] .1129
Failure Code [AS10NT] .1130
Failure Code [B@BAZG] .1131
Failure Code [B@BCNS] .1132
Failure Code [B@BCQA] .1133
Failure Code [B@BCZK] .1135
Failure Code [B@CENS] .1137
Failure Code [B@HANS] .1138
Failure Code [CA115] 1139
Failure Code [CA122] 1140
Failure Code [CA123] 1142
Failure Code [CA131] 1144
Failure Code [CA132] 1146
Failure Code [CA144] 1149
Failure Code [CA145] 1151
Failure Code [CA153] 1153
Failure Code [CA154] 1156
Failure Code [CA187] 1159
Failure Code [CA221] 1161
Failure Code [CA222] 1163
Failure Code [CA227] 1165
Failure Code [CA234] 1166
Failure Code [CA238] 1167
Failure Code [CA239] 1169
Failure Code [CA249] 1171
Failure Code [CA256] 1173
Failure Code [CA271] 1175
Failure Code [CA272] 1177
Failure Code [CA281] 1179
Failure Code [CA322] 1180
Failure Code [CA323] 1182
Failure Code [CA324] 1184
Failure Code [CA325] 1186
Failure Code [CA331] 1188
Failure Code [CA332] 1190
Failure Code [CA343] 1192
Failure Code [CA351] 1193
Failure Code [CA352] 1194
Failure Code [CA356] 1197
Failure Code [CA357] 1199
Failure Code [CA386] 1201
Failure Code [CA428] 1202
Failure Code [CA429] 1204
Failure Code [CA435] 1206
Failure Code [CA441] 1208
Failure Code [CA442] 1210
Failure Code [CA449] 1211
Failure Code [CA451] 1215
Failure Code [CA452] 1218
Failure Code [CA488] 1220
Failure Code [CA515] 1221
Failure Code [CA516] 1223
Failure Code [CA553] 1225
Failure Code [CA555] 1226
Failure Code [CA556] 1227
Failure Code [CA559] 1228
Failure Code [CA595] 1232
Failure Code [CA687] 1233
Failure Code [CA689] 1235
Failure Code [CA691] 1240
Failure Code [CA692] 1242
Failure Code [CA697] 1244
Failure Code [CA698] 1245
Failure Code [CA731] 1246
Failure Code [CA778] 1248
Failure Code [CA1117] .1253
Failure Code [CA1664] .1254
Failure Code [CA1669] .1257
Failure Code [CA1673] .1258
Failure Code [CA1677] .1259
Failure Code [CA1678] .1260
Failure Code [CA1682] .1261
Failure Code [CA1683] .1266
Failure Code [CA1684] .1268
Failure Code [CA1686] .1270
Failure Code [CA1691] .1271
Failure Code [CA1694] .1274
Failure Code [CA1695] .1277
Failure Code [CA1696] .1278
Failure Code [CA1712] .1280
Failure Code [CA1713] .1283
Failure Code [CA1714] .1285
Failure Code [CA1715] .1286
Failure Code [CA1776] .1287
Failure Code [CA1777] .1290
Failure Code [CA1843] .1293
Failure Code [CA1844] .1295
Failure Code [CA1879] .1298
Failure Code [CA1881] .1301
Failure Code [CA1883] .1304
Failure Code [CA1885] .1308
Failure Code [CA1887] .1310
Failure Code [CA1921] .1312
Failure Code [CA1922] .1315
Failure Code [CA1942] .1320
Failure Code [CA1993] .1321
Failure Code [CA2185] .1324
Failure Code [CA2186] .1326
Failure Code [CA2249] .1328
Failure Code [CA2265] .1329
Failure Code [CA2266] .1331
Failure Code [CA2271] .1333
Failure Code [CA2272] .1336
Failure Code [CA2288] .1339
Failure Code [CA2311] .1340
Failure Code [CA2349] .1341
Failure Code [CA2353] .1344
Failure Code [CA2357] .1346
Failure Code [CA2381] .1347
Failure Code [CA2382] .1350
Failure Code [CA2383] .1353
Failure Code [CA2386] .1356
Failure Code [CA2387] .1358
Troubleshooting Flowchart .1362
Failure Code [CA2555] .1363
Failure Code [CA2556] .1366
Failure Code [CA2637] .1369
Failure Code [CA2639] .1371
Failure Code [CA2771] .1374
Failure Code [CA2777] .1380
Failure Code [CA2976] .1383
Failure Code [CA3133] .1385
Failure Code [CA3134] .1387
Failure Code [CA3135] .1389
Failure Code [CA3142] .1393
Failure Code [CA3143] .1394
Failure Code [CA3144] .1395
Failure Code [CA3146] .1397
Failure Code [CA3147] .1398
Failure Code [CA3148] .1399
Failure Code [CA3151] .1401
Failure Code [CA3165] .1407
Failure Code [CA3229] .1409
Failure Code [CA3231] .1411
Failure Code [CA3232] .1413
Failure Code [CA3235] .1417
Failure Code [CA3239] .1419
Failure Code [CA3241] .1422
Failure Code [CA3242] .1425
Failure Code [CA3251] .1428
Failure Code [CA3253] .1430
Failure Code [CA3254] .1433
Failure Code [CA3255] .1436
Failure Code [CA3256] .1439
Failure Code [CA3311] .1441
Failure Code [CA3312] .1443
Failure Code [CA3313] .1446
Failure Code [CA3314] .1447
Failure Code [CA3315] .1448
Failure Code [CA3316] .1451
Failure Code [CA3317] .1452
Failure Code [CA3318] .1453
Failure Code [CA3319] .1456
Failure Code [CA3321] .1457
Failure Code [CA3322] .1459
Failure Code [CA3419] .1462
Failure Code [CA3421] .1464
Failure Code [CA3497] .1466
Failure Code [CA3498] .1467
Failure Code [CA3543] .1468
Failure Code [CA3545] .1475
Failure Code [CA3547] .1477
Failure Code [CA3558] .1478
Failure Code [CA3559] .1480
Failure Code [CA3562] .1482
Failure Code [CA3563] .1484
Failure Code [CA3567] .1487
Failure Code [CA3568] .1490
Failure Code [CA3571] .1497
Failure Code [CA3572] .1499
Failure Code [CA3574] .1501
Failure Code [CA3575] .1504
Failure Code [CA3577] .1506
Failure Code [CA3578] .1508
Failure Code [CA3582] .1510
Failure Code [CA3583] .1519
Failure Code [CA3596] .1521
Failure Code [CA3649] .1524
Failure Code [CA3681] .1526
Failure Code [CA3682] .1528
Failure Code [CA3713] .1531
Failure Code [CA3717] .1534
Failure Code [CA3718] .1535
Failure Code [CA3725] .1536
Failure Code [CA3741] .1539
Failure Code [CA3748] .1540
Failure Code [CA3751] .1543
Failure Code [CA3755] .1545
Failure Code [CA3866] .1547
Failure Code [CA3867] .1551
Failure Code [CA3868] .1554
Failure Code [CA3899] .1558
Failure Code [CA3911] .1560
Failure Code [CA3912] .1564
Failure Code [CA3932] .1566
Failure Code [CA3933] .1568
Failure Code [CA3934] .1570
Failure Code [CA3935] .1573
Failure Code [CA3936] .1575
Failure Code [CA4151] .1577
Failure Code [CA4152] .1581
Failure Code [CA4155] .1585
Failure Code [CA4156] .1588
Failure Code [CA4157] .1591
Failure Code [CA4158] .1593
Failure Code [CA4159] .1594
Failure Code [CA4161] .1595
Failure Code [CA4162] .1597
Failure Code [CA4163] .1600
Failure Code [CA4164] .1602
Failure Code [CA4165] .1604
Failure Code [CA4166] .1606
Failure Code [CA4168] .1608
Failure Code [CA4169] .1611
Failure Code [CA4171] .1613
Failure Code [CA4249] .1616
Failure Code [CA4251] .1618
Failure Code [CA4259] .1620
Failure Code [CA4261] .1623
Failure Code [CA4277] .1626
Failure Code [CA4281] .1630
Failure Code [CA4459] .1634
Failure Code [CA4461] .1637
Failure Code [CA4658] .1640
Failure Code [CA4731] .1644
Failure Code [CA4732] .1645
Failure Code [CA4739] .1646
Failure Code [CA4768] .1647
Failure Code [CA4769] .1649
Failure Code [CA4842] .1652
Failure Code [CA4952] (Machine with KOMTRAX Terminal) .1656
Failure Code [CA4952] (Machine with Gateway Function Controller) 1658
Failure Code [CA5115] .1660
Failure Code [CA5383] .1663
Failure Code [D130KA] .1665
Failure Code [D130KB] .1668
Failure Code [D19JKZ] .1670
Failure Code [D811MC] (Machine with KOMTRAX Terminal) .1673
Failure Code [D811MC] (Machine with Gateway Function Controller) 1674
Failure Code [D862KA] (Machine with KOMTRAX Terminal) .1675
Failure Code [D862KA] (Machine with Gateway Function Controller) 1676
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) .1677
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1679
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) .1681
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1683
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) .1685
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1687
Failure Code [D8G1KT] .1689
Failure Code [D8G6KT] .1690
Failure Code [DAF0MB] .1691
Failure Code [DAF0MC] .1692
Failure Code [DAF8KB] .1693
Failure Code [DAF9KQ] .1694
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) .1695
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1696
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) .1697
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1699
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) .1701
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1703
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) .1705
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1706
Failure Code [DAQW00] .1707
Failure Code [DAZ9KQ] .1708
Failure Code [DAZQKR] .1709
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) .1710
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1715
Failure Code [DB2RKR] .1720
Failure Code [DBE0KT] .1725
Failure Code [DBE1KK] .1726
Failure Code [DBE2KK] .1729
Failure Code [DBE5KK] .1732
Failure Code [DBE6KK] .1734
Failure Code [DBE7KK] .1736
Failure Code [DBE9KQ] .1738
Failure Code [DBELKA] .1739
Failure Code [DBELKB] .1741
Failure Code [DBEQKR] .1743
Failure Code [DBERKR] .1744
Failure Code [DD12KA] .1746
Failure Code [DD12KB] .1748
Failure Code [DD13KA] .1750
Failure Code [DD13KB] .1752
Failure Code [DD14KA] .1754
Failure Code [DD14KB] .1756
Failure Code [DDKFL4] .1758
Failure Code [DDKGL4] .1760
Failure Code [DDKHKA] .1762
Failure Code [DDKHKB] .1764
Failure Code [DDN7KA] .1766
Failure Code [DDN7KB] .1768
Failure Code [DDNLKA] .1770
Failure Code [DDNLKB] .1772
Failure Code [DGS1KA] .1774
Failure Code [DGS1KX] .1776
Failure Code [DGT1KA] .1778
Failure Code [DGT1KX] .1781
Failure Code [DH21KA] .1783
Failure Code [DH21KY] .1785
Failure Code [DHA4KA] .1787
Failure Code [DHAAMA] .1789
Failure Code [DHACMA] .1791
Failure Code [DHTDKA] .1793
Failure Code [DHTDKY] .1795
Failure Code [DK10KA] .1797
Failure Code [DK10KB] .1800
Failure Code [DK30KA] .1802
Failure Code [DK30KX] .1805
Failure Code [DK30KY] .1806
Failure Code [DK30KZ] .1808
Failure Code [DK30L8] .1809
Failure Code [DK31KA] .1810
Failure Code [DK31KY] .1813
Failure Code [DK40KA] .1815
Failure Code [DK40KY] .1817
Failure Code [DK55KX] .1819
Failure Code [DK55KZ] .1820
Failure Code [DK55L8] .1821
Failure Code [DK56KA] .1822
Failure Code [DK56KY] .1824
Failure Code [DK57KA] .1826
Failure Code [DK57KY] .1828
Failure Code [DKH1KA] .1830
Failure Code [DKH1KY] .1833
Failure Code [DLM3KA] .1835
Failure Code [DLM3MB] .1837
Failure Code [DLT3KA] .1838
Failure Code [DLT3KB] .1840
Failure Code [DR21KX] .1842
Failure Code [DR31KX] .1843
Failure Code [DV20KB] .1844
Failure Code [DW5AKA] .1846
Failure Code [DW5AKB] .1848
Failure Code [DW5AKY] .1850
Failure Code [DW7BKA] .1852
Failure Code [DW7BKB] .1854
Failure Code [DW7BKY] .1856
Failure Code [DWN1KA] .1857
Failure Code [DWN1KB] .1859
Failure Code [DWN1KY] .1861
Failure Code [DWN2KA] .1863
Failure Code [DWN2KB] .1865
Failure Code [DWN2KY] .1867
Failure Code [DWN5KA] .1868
Failure Code [DWN5KB] .1870
Failure Code [DWN5KY] .1871
Failure Code [DXA2KA] .1873
Failure Code [DXA2KB] .1875
Failure Code [DXA2KY] .1877
Failure Code [DXH1KA] .1878
Failure Code [DXH1KB] .1880
Failure Code [DXH1KY] .1882
Failure Code [DXH4KA] .1884
Failure Code [DXH4KB] .1886
Failure Code [DXH4KY] .1888
Failure Code [DXH5KA] .1890
Failure Code [DXH5KB] .1892
Failure Code [DXH5KY] .1894
Failure Code [DXH6KA] .1896
Failure Code [DXH6KB] .1898
Failure Code [DXH6KY] .1900
Failure Code [DXH7KA] .1902
Failure Code [DXH7KB] .1904
Failure Code [DXH7KY] .1906
Failure Code [DXH8KA] .1908
Failure Code [DXH8KB] .1910
Failure Code [DXH8KY] .1912
Failure Code [DXJ4KA] .1914
Failure Code [DXJ4KB] .1916
Failure Code [DXJCKA] .1918
Failure Code [DXJCKB] .1920
Failure Code [DXJCKY] .1922
Failure Code [DXJDKA] .1924
Failure Code [DXJDKB] .1926
Failure Code [DXJDKY] .1928
Failure Code [F313KA] .1930
Failure Code [F313KB] .1931
Failure Code [F318KB] .1932
Failure Code [F318KY] .1933
Troubleshooting of Electrical System (E-Mode) .1934
Engine Does Not Start (Engine Does Not Crank) .1934
Manual Preheating System Does Not Operate .1941
Automatic Preheating System Does Not Operate 1944
While Preheating is in Operation, Preheating Monitor Does Not Come On .1946
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1948
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On .1952
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1953
Charge Level Monitor Comes On in Red While Engine is in Operation .1954
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .1956
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1957
Power Train Oil Temperature Monitor Comes On in Red While Engine Runs .1958
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1959
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1960
DEF Level is Not Shown Correctly 1961
Fuel Gauge Does Not Show Normally .1964
Power Train Oil Temperature Gauge Does Not Show Correct Temperature .1966
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature .1967
Operation Mode Does Not Change 1968
Gear Shift Mode Does Not Change .1969
When You Operate Customize Switch Does Not Show Customize Screen 1970
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 1971
Some Areas of Machine Monitor Screen are Not Shown 1972
REVERSE Slow Mode Function Does Not Operate Correctly .1973
Alarm Buzzer Does Not Operate or Does Not Stop Operation 1974
Service Meter is Not Shown While Starting Switch is in OFF Position .1975
Service Mode Cannot be Selected .1976
Horn Does Not Sound .1977
Horn Does Not Stop 1979
Backup Alarm Does Not Sound .1980
Backup Alarm Does Not Stop Operation 1982
Headlamp Does Not Come On .1983
Rear Lamp Does Not Come On 1987
No Wiper Operates .1990
Front Wiper Does Not Operate 1994
Rear Wiper Does Not Operate .1997
Left Door Wiper Does Not Operate 2000
Right Door Wiper Does Not Operate .2003
Front Washer Does Not Operate .2006
Rear Washer Does Not Operate 2008
Left Door Washer Does Not Operate .2010
Right Door Washer Does Not Operate 2012
KOMTRAX System Does Not Operate Correctly .2014
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2015
Information Shown in Troubleshooting Table (H-Mode) .2015
System Chart of Hydraulic and Mechanical Systems 2016
Failure Mode and Cause Table 2018
Machine Lacks Power (Drawbar Pull is Not Sufficient) 2026
Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2028
Machine Does Not Move Off at All Gear Speeds 2029
Machine Travels Only in One Direction, Forward or in Reverse 2031
Large Time Lag is in Gear Shifting or Directional Change 2032
Brake Does Not Work .2034
Power Train Oil Overheats .2035
Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor .2037
Torque Converter Lockup Clutch Does Not Engage 2038
Machine Cannot be Steered (Machine Does Not Turn Left or Right) .2039
Steering Speed or Power is Not Sufficient .2040
All Work Equipment Operate Slowly .2041
All Work Equipment Do Not Operate .2042
Blade Lift Speed or Power is Low 2043
Blade Tilt Speed or Power is Low 2044
Blade Angle Speed or Power is Low .2045
Ripper Lift Speed or Power is Low .2046
Hydraulic Drift of Blade Lift is Large 2047
Hydraulic Drift of Tilted Blade is Large 2048
Hydraulic Drift of Lifted Ripper is Large .2049
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2050
Unusual Noise is Heard from Around Fan 2052
Troubleshooting of Engine (S-Mode) 2053
Information Shown in Troubleshooting Table (S-Mode) .2053
Engine Does Not Crank When Starting Switch is Turned to Start Position 2054
Engine Cranks but No Exhaust Smoke Comes Out 2055
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2056
Engine Startability is Unsatisfactory .2058
Engine Does Not Pick Up Smoothly 2060
Engine Stops During Operation .2062
Engine Does Not Rotate Smoothly .2064
Engine Lacks Output (or Lacks Power) 2065
KDPF Becomes Clogged in a Short Time 2067
Engine Oil Consumption is Excessive .2069
Engine Oil Becomes Dirty Quickly 2070
Fuel Consumption is Excessive .2071
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2072
Engine Oil Pressure Drops .2073
Fuel Mixes Into Engine Oil 2075
Water Mixes Into Engine Oil (Milky) .2076
Coolant Temperature Increases Too High (Overheat) .2077
Unusual Noise is Heard 2078
Vibration is Excessive 2079
Air Cannot be Bled from Fuel Circuit 2080
Active Regeneration is Done Frequently 2081
Active Regeneration Continues Long 2083
White Smoke is Exhausted During Active Regeneration .2084
DEF Consumption is Excessive 2085
There is an Unusual Smell (Irritating Odor) .2087
Foreign Materials Enter DEF (DEF Increases) .2088
50 Disassembly and Assembly .2089
Table of Contents .2090
Precautions Before Work .2096
Abbreviation List .2097
Related Information on Disassembly and Assembly .2103
How to Read This Manual .2103
Coating Materials List 2104
Special Tool List .2109
Sketches of Special Tools .2131
Engine and Cooling System .2152
Remove and Install Supply Pump Assembly .2152
Remove Supply Pump Assembly .2152
Install Supply Pump Assembly 2156
Remove and Install Injector Assembly 2161
How to Remove Injector Assembly .2162
How to Install Injector Assembly 2169
Remove and Install Cylinder Head Assembly .2180
How to Remove Cylinder Head Assembly 2181
How to Install Cylinder Head Assembly .2191
Remove and Install EGR Valve Assembly .2207
Remove EGR Valve Assembly .2207
Install EGR Valve Assembly 2208
Remove and Install EGR Cooler Assembly 2209
How to Remove EGR Cooler Assembly .2209
How to Install EGR Cooler Assembly 2210
Remove and Install Starter Assembly .2212
Remove Starting Motor Assembly 2212
Install Starting Motor Assembly .2214
Remove and Install Alternator Belt 2217
Remove Alternator Belt 2217
Install Alternator Belt .2218
Remove and Install Automatic Tensioner 2220
Remove Automatic Tensioner 2220
Install Automatic Tensioner .2220
Remove and Install Expansion Tank Assembly 2221
How to Remove Expansion Tank Assembly .2221
How to Install Expansion Tank Assembly 2225
Remove and Install Radiator Assembly 2230
How to Remove Radiator Assembly .2230
How to Install Radiator Assembly 2233
Remove and Install Hydraulic Oil Cooler Assembly 2237
How to Remove Hydraulic Oil Cooler Assembly .2237
How to Install Hydraulic Oil Cooler Assembly 2239
Remove and Install Aftercooler Assembly .2243
Remove Aftercooler Assembly .2243
Install Aftercooler Assembly 2245
Remove and Install Power Train Oil Cooler Assembly 2248
How to Remove Power Train Oil Cooler Assembly .2248
How to Install Power Train Oil Cooler Assembly 2250
Remove and Install Cooling Fan Drive Assembly .2253
Remove Cooling Fan Drive Assembly .2253
Install Cooling Fan Drive Assembly 2254
Remove and Install Cooling Fan Motor Assembly .2257
Remove Cooling Fan Motor Assembly .2257
Install Cooling Fan Motor Assembly 2259
Remove and Install Engine Assembly 2261
Remove Engine Assembly 2261
Install Engine Assembly .2265
Remove and Install Engine Front Oil Seal 2271
How to Remove Engine Front Oil Seal .2271
How to Install Engine Front Oil Seal 2273
Remove and Install Engine Rear Oil Seal .2277
How to Remove Engine Rear Oil Seal 2277
How to Install Engine Rear Oil Seal .2281
Remove and Install Engine Hood Assembly .2289
How to Remove Engine Hood Assembly 2289
How to Install Engine Hood Assembly .2293
Remove and Install Fuel Tank Assembly .2297
Remove Fuel Tank Assembly .2297
Install Fuel Tank Assembly 2300
Remove and Install DEF Tank Assembly 2303
How to Remove DEF Tank Assembly .2304
How to Install DEF Tank Assembly 2308
Remove and Install DEF Tank Sensor Flange Assembly 2312
How to Remove DEF Tank Sensor Flange Assembly .2313
How to Install DEF Tank Sensor Flange Assembly 2317
Remove and Install DEF Tank Sensor 2324
Remove DEF Tank Sensor 2324
Install DEF Tank Sensor .2325
Remove and Install DEF Tank Strainer 2332
Remove DEF Tank Strainer 2332
Install DEF Tank Strainer .2332
Remove and Install KDPF Assembly 2333
How to Remove KDPF Assembly .2333
How to Install KDPF Assembly 2337
Disassemble and Assemble KDPF Assembly 2341
Disassemble KDPF Assembly .2341
Assemble KDPF Assembly 2345
Remove and Install SCR Assembly .2351
How to Remove SCR Assembly 2351
How to Install SCR Assembly .2353
Remove and Install KDPF and SCR Assembly 2356
How to Remove KDPF and SCR Assembly .2356
Install KDPF and SCR Assembly .2363
Remove and Install KCCV Assembly 2370
Remove KCCV Assembly 2370
Install KCCV Assembly .2372
Remove and Install DEF Mixing Tube 2374
Remove DEF Mixing Tube 2374
Install DEF Mixing Tube .2377
Remove and Install DEF Injector .2382
Remove DEF Injector .2382
Install DEF Injector 2385
Remove and Install DEF Pump .2389
Remove DEF Pump .2389
Install DEF Pump 2392
Remove and Install DEF Hose .2395
Remove DEF Hose .2395
Install DEF Hose 2400
Remove and Install Air Cleaner Assembly .2405
Remove Air Cleaner Assembly .2405
Install Air Cleaner Assembly 2406
Remove and Install Air Conditioner Compressor Assembly 2408
Remove Air Conditioner Compressor Assembly 2408
How to Install Air Conditioner Compressor Assembly 2410
Remove and Install Air Conditioner Condenser Assembly .2413
How to Remove Air Conditioner Condenser Assembly 2413
How to Install Air Conditioner Condenser Assembly .2415
Power Train .2417
Remove and Install Damper Assembly 2417
How to Remove Damper Assembly .2417
How to Install Damper Assembly 2420
Remove and Install Power Train Unit Assembly 2425
Remove Power Train Unit Assembly 2425
How to Install Power Train Unit Assembly 2430
Disconnect and Connect Power Train Unit Assembly 2436
How to Disconnect Power Train Unit Assembly .2436
Connect Power Train Unit Assembly .2441
Disassemble and Assemble PTO Assembly .2447
Disassemble PTO Assembly 2447
Assemble PTO Assembly .2450
Disassemble and Assemble Torque Converter Assembly 2454
Disassemble Torque Converter Assembly .2455
Assemble Torque Converter Assembly 2461
Disassemble and Assemble Transmission Assembly 2470
Disassemble Transmission Assembly .2471
Assemble Transmission Assembly 2489
Disassemble and Assemble HSS Assembly .2502
Disassemble HSS Assembly 2504
Assemble HSS Assembly .2515
Remove and Install HSS Motor Assembly .2532
Remove HSS Motor Assembly .2532
How to Install HSS Motor Assembly .2534
Remove and Install Final Drive Assembly .2537
Remove Final Drive Assembly .2537
Install Final Drive Assembly 2540
Disassemble and Assemble Final Drive Assembly .2543
Disassemble Final Drive Assembly 2544
Assemble Final Drive Assembly .2549
Undercarriage and Frame .2557
Remove and Install Track Frame Assembly .2557
Remove Track Frame Assembly .2557
Install Track Frame Assembly 2559
Remove and Install Idler Assembly .2562
Remove Idler Assembly .2562
Install Idler Assembly 2563
Disassemble and Assemble Idler Assembly .2565
Disassemble Idler Assembly 2565
Assemble Idler Assembly .2567
Remove and Install Recoil Spring Assembly .2571
Remove Recoil Spring Assembly .2571
Install Recoil Spring Assembly 2571
Disassemble and Assemble Recoil Spring Assembly .2573
Disassemble Recoil Spring Assembly 2573
Assemble Recoil Spring Assembly .2576
Remove and Install Track Roller Assembly 2579
Remove Track Roller Assembly 2579
Install Track Roller Assembly .2580
Disassemble and Assemble Track Roller Assembly 2581
Disassemble Track Roller Assembly .2581
Assemble Track Roller Assembly 2583
Remove and Install Carrier Roller Assembly 2586
Remove Carrier Roller Assembly 2586
Install Carrier Roller Assembly .2587
Disassemble and Assemble Carrier Roller Assembly 2588
Disassemble Carrier Roller Assembly .2588
Assemble Carrier Roller Assembly 2589
Remove and Install Pivot Shaft Assembly .2592
Remove Pivot Shaft Assembly .2592
Install Pivot Shaft Assembly 2593
Separate and Connect Track Assembly .2594
Examine Before Separation of Track Assembly .2594
Separate Track Assembly (Standard) 2594
How to Separate Track Assembly (When Track Frame Has Internal Defect) .2595
Install Track Assembly 2596
Separate and Connect PLUS Type Track Assembly .2599
Separate PLUS Type Track Assembly Generally .2599
Install PLUS Type Track Assembly 2599
Disassemble and Assemble Track Assembly Generally .2600
How to Disassemble Full Track Shoes Assembly 2600
How to Assemble Full Track Shoes Assembly .2603
Disassemble and Assemble PLUS Type Track Assembly Generally .2615
Disassemble PLUS Type Track Assembly Generally 2616
How to Assemble PLUS Type Track Shoes Assembly Generally 2617
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2632
Disassemble One Track Link Assembly in Field (Track Assembly) .2633
Assemble One Track Link Assembly in Field (Track Assembly) 2634
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2641
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) .2642
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2644
Remove and Install Equalizer Bar Assembly .2648
Remove Equalizer Bar Assembly .2648
Install Equalizer Bar Assembly 2649
Disassemble and Assemble Equalizer Bar Bushing 2651
Disassemble Equalizer Bar Bushing .2651
Assemble Equalizer Bar Bushing 2651
Hydraulic System 2653
Remove and Install Hydraulic Tank Assembly 2653
Remove Hydraulic Tank Assembly 2653
How to Install Hydraulic Tank Assembly 2656
Remove and Install HSS Pump and Cooling Fan Pump Assembly .2661
How to Remove HSS Pump and Cooling Fan Pump Assembly 2661
How to Install HSS Pump and Cooling Fan Pump Assembly .2662
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2665
Remove Power Train Pump and Steering Lubrication Pump Assembly 2665
Install Power Train Pump and Steering Lubrication Pump Assembly .2667
Remove and Install Scavenging Pump Assembly .2670
Remove Scavenging Pump Assembly .2670
Install Scavenging Pump Assembly 2670
Remove and Install 5 Spool Control Valve Assembly .2672
How to Remove 5 Spool Control Valve Assembly 2672
How to Install 5 Spool Control Valve Assembly .2674
Remove and Install 4 Spool Control Valve Assembly .2677
How to Remove 4 Spool Control Valve Assembly 2677
How to Install 4 Spool Control Valve Assembly .2679
Disassemble and Assemble Blade PPC Valve 2683
How to Disassemble Blade PPC Valve 2683
How to Assemble Blade PPC Valve .2683
Disassemble and Assemble Ripper PPC Valve .2685
How to Disassemble Ripper PPC Valve .2685
How to Assemble Ripper PPC Valve 2685
Work Equipment 2687
Remove and Install Straight Tilt Power Pitch Dozer Blade Assembly .2687
How to Remove Straight Tilt Power Pitch Dozer Blade Assembly 2687
How to Install Straight Tilt Power Pitch Dozer Blade Assembly .2689
Remove and Install Power Angle Power Tilt Dozer Blade Assembly 2693
How to Remove Power Angle Power Tilt Dozer Blade Assembly .2693
How to Install Power Angle Power Tilt Dozer Blade Assembly 2695
Remove and Install Ripper Assembly 2698
Remove Ripper Assembly 2698
Install Ripper Assembly .2701
How to Disassemble and Assemble Work Equipment Cylinder Assembly 2704
How to Disassemble Work Equipment Cylinder Assembly .2705
How to Assemble Work Equipment Cylinder Assembly 2708
CAB Related Parts .2713
Remove and Install Operator Cab Assembly 2713
How to Remove Operator Cab Assembly .2713
Install Operator CAB Assembly .2720
Remove and Install Operator Cab Glass (Adhered Glass) .2729
Remove Operator CAB Glass (Adhered Glass) .2729
Install Operator CAB Glass (Adhered Glass) 2730
Remove and Install Air Conditioner Unit Assembly 2735
Remove Air Conditioner Unit Assembly 2735
Install Air Conditioner Unit Assembly .2740
Remove and Install Operator Seat 2746
Remove Operator’s Seat 2746
Install Operator’s Seat .2748
How to Remove and Install Seat Belt .2750
How to Remove Seat Belt .2750
How to Install Seatbelt .2751
Electrical System .2752
Remove and Install Engine Controller Assembly .2752
Remove Engine Controller Assembly .2752
Install Engine Controller Assembly 2753
Remove and Install Power Train Controller Assembly 2756
Remove Power Train Controller Assembly 2756
Install Power Train Controller Assembly .2757
Remove and Install Machine Monitor Assembly .2759
Remove Machine Monitor Assembly .2759
Install Machine Monitor Assembly 2760
Remove and Install Mass Air Flow and Temperature Sensor .2762
How to Remove Mass Air Flow and Temperature Sensor 2762
How to Install Mass Air Flow and Temperature Sensor .2763
Remove and Install KCCV Crankcase Pressure Sensor .2764
How to Remove KCCV Crankcase Pressure Sensor 2764
How to Install KCCV Crankcase Pressure Sensor .2765
Remove and Install SCR Temperature Sensor .2766
Remove SCR Temperature Sensor .2766
Install SCR Temperature Sensor 2767
Remove and Install Rearview Camera 2769
Remove Rearview Camera 2769
Install Rearview Camera .2769
Remove and Install KOMTRAX Terminal Assembly 2771
Remove KOMTRAX Terminal Assembly 2771
Install KOMTRAX Terminal Assembly .2773
Remove and Install Gateway Function Controller Assembly .2775
How to Remove Gateway Function Controller Assembly 2775
How to Install Gateway Function Controller Assembly .2778
Remove and Install Communication Terminal .2782
How to Remove Communication Terminal 2782
How to Install Communication Terminal .2785
60 Maintenance Standard .2789
Table of Contents .2790
Abbreviation List .2792
Engine and Cooling System .2798
Maintenance Standard for Engine Mount .2798
Maintenance Standard for Damper .2799
Maintenance Standard for Cooling System .2801
Maintenance Standard for Cooling Fan Pump .2803
Maintenance Standard for Servo Valve 2804
Maintenance Standard for Cooling Fan Motor 2805
Power Train .2807
Maintenance Standard for Universal Joint 2807
Maintenance Standard for Power Train Mount 2808
Maintenance Standard for Torque Converter and PTO .2810
Maintenance Standard for Lockup Clutch ECMV .2813
Maintenance Standard for Transmission .2814
Maintenance Standard for Transmission Control Valve .2819
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV .2820
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 2821
Maintenance Standard for Transmission Lubrication Relief Valve 2822
Maintenance Standard for Bevel Gear Shaft, HSS, and Brake .2823
Maintenance Standard for Brake Valve 2828
Maintenance Standard for Final Drive 2830
Maintenance Standard for Sprocket for Conventional Type Track Shoes .2832
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2833
Maintenance Standard for Sprocket for PLUS Type Track Shoes .2835
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2836
Undercarriage and Frame .2838
Maintenance Standard for Main Frame .2838
Maintenance Standard for Suspension .2839
Maintenance Standard for Track Frame and Idler Cushion 2841
Maintenance Standard for Idler 2843
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2845
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2846
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2847
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2848
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes .2849
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes .2850
Maintenance Standard for Conventional Type Track Shoes 2851
Maintenance Standard for PLUS Type Track Shoes 2853
Maintenance Standard for Single Shoes .2855
Maintenance Standard for Swamp Shoes 2856
Hydraulic System 2857
Maintenance Standard for Hydraulic Tank .2857
Maintenance Standard for Scavenging Pump 2858
Maintenance Standard for Steering Lubrication Pump and Power Train Pump .2859
Maintenance Standard for Work Equipment and HSS Pump 2860
Maintenance Standard for PC-EPC Valve .2861
Maintenance Standard for HSS Motor 2862
Maintenance Standard for Control Valve 2864
Maintenance Standard for Blade PPC Valve 2872
Maintenance Standard for Ripper PPC Valve .2874
Maintenance Standard for Angle Control EPC Valve 2876
Maintenance Standard for Quick Drop Valve .2877
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer and Angle Dozer Series) .2879
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Tilt Pitch Dozer Series) .2880
Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Angle Power Tilt Dozer Series) .2881
Work Equipment 2882
Maintenance Standard for Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series) 2882
Maintenance Standard for Front Work Equipment (For Power Angle Power Tilt Dozer Series) .2885
Maintenance Standard for Front Work Equipment (Angle Dozer Series) 2888
Maintenance Standard for Cutting Edge and End Bit .2891
Maintenance Standard for Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series) 2893
Maintenance Standard for Blade Lift Cylinder (For Power Angle Power Tilt Dozer Series) 2894
Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer, and Angle Dozer Series) 2895
Maintenance Standard for Blade Tilt Cylinder (For Power Angle Power Tilt Dozer Series) 2896
Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series) .2897
Maintenance Standard for Blade Angle Cylinder (For Power Angle Power Tilt Dozer Series) .2898
Maintenance Standard for Fixed Multi-Shank Ripper .2899
Maintenance Standard for Ripper Lift Cylinder .2900
CAB Related Parts .2901
Maintenance Standard for CAB Mount 2901
80 Appendix .2903
Table of Contents .2904
Precautions Before Work .2906
Abbreviation List .2907
Air Conditioner System 2913
Precautions for Refrigerant .2913
Air Conditioner Component .2914
Specifications of Air Conditioner .2916
Structure and Function of Refrigeration Cycle .2917
Outline of Refrigeration Cycle 2918
Component Parts of Air Conditioner System .2920
Air Conditioner Unit 2920
Configuration Diagram of Air Conditioner Unit .2920
Function of Air Conditioner Unit 2922
Component Parts of Air Conditioner Unit .2924
Function of Evaporator as Air Conditioner Unit Component 2925
Function of Heater Core as Air Conditioner Unit Component .2925
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .2925
Function of Servo Motor as Air Conditioner Unit Component .2925
Structure of Expansion Valve as Air Conditioner Unit Component 2926
Function of Expansion Valve as Air Conditioner Unit Component .2926
Operate Expansion Valve as Air Conditioner Unit Component .2926
Function of Dual Pressure Switch 2927
Air Conditioner Controller 2928
Structure of Air Conditioner Controller .2928
Compressor 2929
Structure of Compressor .2929
Specifications of Compressor 2929
Function of Compressor 2929
Condenser .2930
Structure of Standard Core Condenser 2930
Specifications of Standard Core Condenser .2930
Function of Standard Core Condenser .2930
Structure of Wide Core Condenser 2931
Specifications of Wide Core Condenser .2931
Function of Wide Core Condenser .2931
Receiver Drier 2932
Structure of Receiver Dryer .2932
Specifications of Receiver Dryer 2932
Function of Receiver Dryer 2932
Air Conditioner Related Sensors .2933
Structure of Sunlight Sensor 2933
Function of Sunlight Sensor .2933
Structure of Outside Temperature Sensor .2933
Function of Outside Air Temperature Sensor 2933
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .2935
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2937
System Diagram of Air Conditioner .2939
Input and Output Signals of Air Conditioner Controller 2940
Function of Air Conditioner Controller 2941
Locations of Air Conditioner Parts and Layout of Connectors .2942
Examine Air Leakage (Duct) 2951
How to Examine Air Leakage (Duct) .2951
Explanation for Test of Air Conditioner with Self-Diagnosis Function 2954
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .2955
Examine Vent (Mode) Changeover 2956
How to Examine Vent (Mode) Changeover .2956
Examine Fresh/Recirc Air Changeover .2957
How to Examine Fresh/Recirc Air Changeover 2957
Examine Sunlight Sensor .2958
How to Examine Sunlight Sensor 2958
Examine Refrigerant (Dual) Pressure Switch 2959
How to Examine Refrigerant (Dual) Pressure Switch .2959
Examine Relay .2960
How to Examine Relay 2960
Air Conditioner Troubleshooting Chart 1 .2961
Air Conditioner Troubleshooting Chart 2 .2962
Information Shown in Troubleshooting Table 2965
Failure Code [879AKA] .2966
Failure Code [879AKB] .2967
Failure Code [879BKA] .2968
Failure Code [879BKB] .2970
Failure Code [879CKA] .2972
Failure Code [879CKB] .2973
Failure Code [879DKZ] .2974
Failure Code [879EMC] .2976
Failure Code [879FMC] .2977
Failure Code [879GKX] .2978
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2980
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .2982
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2986
Troubleshooting for Fresh/Recirc Air Changeover .2988
Troubleshooting by Gauge Pressure .2990
Connect Service Tool 2993
How to Connect Service Tool .2993
Precautions for Disconnection and Connection of Air Conditioner Piping 2995
Handle Compressor Oil .2997
90 Circuit Diagrams .2999
Table of Contents .3000
Abbreviation List .3001
Hydraulic Circuit Diagram .3007
Symbols Used in Hydraulic Circuit Diagram .3007
Hydraulic Circuit Diagram (For Straight Tilt and SIGMADOZER) 3011
Hydraulic Circuit Diagram (For Straight Tilt Power Pitch Dozer) .3013
Hydraulic Circuit Diagram (For Power Angle Power Tilt Dozer) 3015
Hydraulic Circuit Diagram (For Straight Tilt and SIGMADOZER) (3D Machine Control Spec) 3017
Hydraulic Circuit Diagram (For Straight Tilt Power Pitch Dozer) (3D Machine Control Spec) .3019
Hydraulic Circuit Diagram (For Power Angle Power Tilt Dozer) (3D Machine Control Spec) 3021
Power Train Hydraulic Circuit Diagram .3023
Electrical Circuit Diagram 3025
Symbols Used in Electric Circuit Diagram 3025
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/16) .3029
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/16) .3031
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/16) .3033
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/16) .3035
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/16) .3037
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/16) .3039
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/16) .3041
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/16) .3043
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/16) .3045
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/16) 3047
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/16) 3049
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (12/16) 3051
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (13/16) 3053
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (14/16) 3055
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (15/16) 3057
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (16/16) 3059
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/18) 3061
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/18) 3063
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/18) 3065
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/18) 3067
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/18) 3069
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/18) 3071
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/18) 3073
Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/18) 3075
Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/18) 3077
Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/18) .3079
Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/18) .3081
Electrical Circuit Diagram (Machine with Gateway Function Controller) (12/18) .3083
Electrical Circuit Diagram (Machine with Gateway Function Controller) (13/18) .3085
Electrical Circuit Diagram (Machine with Gateway Function Controller) (14/18) .3087
Electrical Circuit Diagram (Machine with Gateway Function Controller) (15/18) .3089
Electrical Circuit Diagram (Machine with Gateway Function Controller) (16/18) .3091
Electrical Circuit Diagram (Machine with Gateway Function Controller) (17/18) .3093
Electrical Circuit Diagram (Machine with Gateway Function Controller) (18/18) .3095
Index 3097

DESCRIPTION:

Komatsu Bulldozer  D65EX-18E0,D65PX-18E0,D65WX-18E0 Shop Manual SEN06756-06 – PDF DOWNLOAD

• SERIAL NUMBERS
  D65EX- 91845          and up
  D65PX- 91845          and up
  D65WX-91845          and up

G.B 27/12/24