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KOMATSU D65EXi-18E0 D65PXi-18E0 BULLDOZER SHOP MANUAL SEN06898-05 – PDF DOWNLOAD
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KOMATSU D65EXi-18E0 D65PXi-18E0 BULLDOZER SHOP MANUAL SEN06898-05 – PDF DOWNLOAD
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KOMATSU D65EXi-18E0 D65PXi-18E0 BULLDOZER SHOP MANUAL SEN06898-05 – PDF DOWNLOAD
Language : English
Pages : 3414
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D65EXi-18E0 D65PXi-18E0 BULLDOZER SHOP MANUAL SEN06898-05 – PDF DOWNLOAD
Cover...................................................................................................................................................... 1 00 Index and Foreword................................................................................................................................. 3 Index............................................................................................................................................. 4 Foreword, Safety, Basic Information............................................................................................................... 25 How to Read the Shop Manual................................................................................................................... 25 Safety Notice for Operation................................................................................................................... 27 Precautions to Prevent Fire................................................................................................................... 35 Procedures If Fire Occurs..................................................................................................................... 37 Precautions for Disposing of Waste Materials.................................................................................................. 38 Procedures for Exhaust Gas Regulations........................................................................................................ 39 Precautions for DEF........................................................................................................................... 40 General Character and Precautions for Handling............................................................................................ 40 Precautions for Adding.................................................................................................................... 40 Precautions for Storage................................................................................................................... 40 Precautions for Fire Hazard and Leakage................................................................................................... 40 Other Precautions......................................................................................................................... 40 Store DEF..................................................................................................................................... 41 Precautions When You Handle Hydraulic Equipment............................................................................................... 42 Precautions When You Disconnect and Connect Pipings........................................................................................... 45 Precautions When You Handle Electrical Equipment.............................................................................................. 52 Precautions When You Handle Fuel System Equipment............................................................................................. 54 Precautions When You Handle Intake System Equipment........................................................................................... 55 Practical Use of KOMTRAX...................................................................................................................... 56 Disconnect and Connect Push-Pull Type Coupler................................................................................................. 57 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................................... 57 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................................... 58 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................................... 59 Precautions for Disconnection and Connection of Connectors.................................................................................... 61 How to Disconnect and Connect Deutsch Connector............................................................................................... 65 How to Disconnect and Connect Slide Lock Type Connector....................................................................................... 66 How to Disconnect and Connect Connector with Lock to Pull..................................................................................... 68 How to Disconnect and Connect Connector with Lock to Push..................................................................................... 69 How to Disconnect and Connect Connector with Housing to Rotate................................................................................ 71 How to Read the Codes for Electric Cable...................................................................................................... 72 Explanation of Terms for Maintenance Standard................................................................................................. 76 Standard Tightening Torque Table.............................................................................................................. 79 Conversion Table.............................................................................................................................. 86 Abbreviation List............................................................................................................................. 91 01 Specifications..................................................................................................................................... 95 Table of Contents................................................................................................................................. 96 Specifications.................................................................................................................................... 97 Specification Drawing......................................................................................................................... 97 Specification Drawing: D65EXI-18E0........................................................................................................ 97 Specification Drawing: D65PXI-18E0........................................................................................................ 99 Specifications................................................................................................................................ 101 Specification: D65EXI-18E0................................................................................................................ 101 Specification: D65PXI-18E0................................................................................................................ 107 Weight Table.................................................................................................................................. 112 Weight Table: D65EXI-18E0................................................................................................................. 112 Weight Table: D65PXI-18E0................................................................................................................. 115 Fuel, Coolant, Lubricants (For European Union)................................................................................................ 117 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................................ 117 Fuel, Coolant, Lubricant (Turkey)............................................................................................................. 119 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................................ 119 10 Structure and Function............................................................................................................................. 121 Table of Contents................................................................................................................................. 122 Urea SCR System................................................................................................................................... 126 Layout Drawing of Urea SCR System............................................................................................................. 126 Urea SCR System Diagram....................................................................................................................... 128 Function of Urea SCR System................................................................................................................... 129 FUNCTION OF DEF SYSTEM(APPLICABLE MACHINE: 96001 to 96348)................................................................................ 129 FUNCTION OF DEF SYSTEM(APPLICABLE MACHINE: 96349 and up).................................................................................. 131 Inducement Strategy....................................................................................................................... 133 Component Parts of Urea SCR System............................................................................................................ 147 DEF Mixing Tube........................................................................................................................... 147 SCR Assembly.............................................................................................................................. 148 DEF Tank.................................................................................................................................. 150 DEF Pump.................................................................................................................................. 152 DEF Injector.............................................................................................................................. 154 DEF Hose.................................................................................................................................. 155 DEF Tank Heating Valve.................................................................................................................... 156 Boot-up System.................................................................................................................................... 157 Layout Drawing of Boot-up System.............................................................................................................. 157 System Operating Lamp System.................................................................................................................. 159 System Diagram of System Operating Lamp System............................................................................................ 159 Function of Operation Lamp System......................................................................................................... 159 Battery Disconnect Switch..................................................................................................................... 161 Layout Drawing of Battery Disconnect Switch............................................................................................... 161 Function of Battery Disconnect Switch..................................................................................................... 161 Engine System..................................................................................................................................... 163 Layout Drawing of Engine System............................................................................................................... 163 Engine Control System......................................................................................................................... 165 Layout Drawing of Engine Control System................................................................................................... 165 System Diagram of Engine Control.......................................................................................................... 167 Function of Engine Control System......................................................................................................... 169 Automatic Idle Stop System.................................................................................................................... 171 System Diagram of Automatic Idle Stop System.............................................................................................. 171 Function of Automatic Idle Stop System.................................................................................................... 171 Component Parts of Engine System.............................................................................................................. 174 Damper.................................................................................................................................... 174 VGT....................................................................................................................................... 176 EGR System................................................................................................................................ 180 EGR Valve................................................................................................................................. 182 EGR Cooler................................................................................................................................ 184 KCCV System............................................................................................................................... 186 KCCV Ventilator........................................................................................................................... 188 KDPF...................................................................................................................................... 190 Cooling System.................................................................................................................................... 194 Layout Drawing of Cooling System.............................................................................................................. 194 Specifications of Cooling System.......................................................................................................... 195 Cooling Fan Control System.................................................................................................................... 196 System Diagram of Cooling Fan Control System.............................................................................................. 196 Function of Cooling Fan Control System.................................................................................................... 197 Component Parts of Cooling System............................................................................................................. 199 Cooling Fan Pump.......................................................................................................................... 199 Cooling Fan Motor......................................................................................................................... 208 Hydraulic Oil Cooler Bypass Valve......................................................................................................... 215 Control System.................................................................................................................................... 216 Layout Drawing of Control System.............................................................................................................. 216 Machine Monitor System........................................................................................................................ 217 System Diagram of Machine Monitor System.................................................................................................. 217 Function of Machine Monitor System........................................................................................................ 217 KOMTRAX System................................................................................................................................ 219 System Diagram of KOMTRAX System.......................................................................................................... 219 Function of KOMTRAX System................................................................................................................ 219 Component Parts of Control System............................................................................................................. 220 Machine Monitor........................................................................................................................... 220 Gateway Function Controller............................................................................................................... 237 Communication Terminal.................................................................................................................... 240 Power Train Controller.................................................................................................................... 242 Engine Controller......................................................................................................................... 246 Hydraulic System.................................................................................................................................. 253 Layout Drawing of Hydraulic System............................................................................................................ 253 CLSS.......................................................................................................................................... 254 Structure of CLSS......................................................................................................................... 254 Function of CLSS.......................................................................................................................... 255 Component Parts of Hydraulic System........................................................................................................... 257 Hydraulic Tank............................................................................................................................ 257 Work Equipment and HSS Pump............................................................................................................... 259 LS Valve.................................................................................................................................. 265 PC Valve.................................................................................................................................. 270 PC-EPC Valve.............................................................................................................................. 275 Control Valve............................................................................................................................. 278 Power Train System................................................................................................................................ 309 Layout Drawing of Power Train System.......................................................................................................... 309 Operation of Power Train System............................................................................................................... 312 Transmission, Steering, and Brake Control..................................................................................................... 313 Layout Drawing of Transmission, Steering, and Brake Control System........................................................................ 313 Function of Transmission, Steering, and Brake Control..................................................................................... 314 Palm Command Control System................................................................................................................... 315 Palm Command Control System Diagram....................................................................................................... 315 HSS System.................................................................................................................................... 319 HSS System Diagram........................................................................................................................ 319 Function of HSS System.................................................................................................................... 320 Centralized Pressure Pickup Port.............................................................................................................. 322 Layout Drawing of Centralized Pressure Pickup Port........................................................................................ 322 Function of Centralized Pressure Pickup Port.............................................................................................. 322 Component Parts of Power Train System......................................................................................................... 323 Universal Joint........................................................................................................................... 323 Power Train Mount......................................................................................................................... 324 Torque Converter and PTO.................................................................................................................. 325 Lockup Clutch ECMV........................................................................................................................ 331 Transmission.............................................................................................................................. 334 Transmission Control Valve................................................................................................................ 346 Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV................................................................................ 348 Main Relief Valve and Torque Converter Relief Valve....................................................................................... 353 Transmission Lubrication Relief Valve..................................................................................................... 355 Bevel Gear Shaft, HSS, and Brake.......................................................................................................... 356 Brake Valve............................................................................................................................... 375 Final Drive............................................................................................................................... 379 Scavenging Pump........................................................................................................................... 383 Steering Lubrication Pump and Power Train Pump............................................................................................ 384 HSS Motor................................................................................................................................. 385 Electric Steering Electric Lever.......................................................................................................... 391 Work Equipment System............................................................................................................................. 394 Work Equipment Control........................................................................................................................ 394 Layout Drawing of Work Equipment Control.................................................................................................. 394 Function of Work Equipment Control........................................................................................................ 395 Layout of Tilt Dozer and Power Tilt Pitch Dozer Series........................................................................................ 397 Layout Drawing of Fixed Multi-Shank Ripper.................................................................................................... 398 Component Parts of Work Equipment System...................................................................................................... 399 Self-Pressure Reducing Valve.............................................................................................................. 399 Work Equipment Lock Solenoid Valve........................................................................................................ 405 Blade PPC Valve........................................................................................................................... 408 Ripper PPC Valve.......................................................................................................................... 414 Blade Pitch Selector Solenoid Valve....................................................................................................... 417 Pilot Circuit Accumulator................................................................................................................. 418 Quick Drop Valve.......................................................................................................................... 419 Piston Valve.............................................................................................................................. 421 ICT System........................................................................................................................................ 422 Layout Drawing of ICT System.................................................................................................................. 422 System Diagram of ICT Control System.......................................................................................................... 424 Blade Control System.......................................................................................................................... 426 Function of Blade Control System.......................................................................................................... 426 Simple Grading Mode System Diagram........................................................................................................ 428 Function of Simple Grading Mode........................................................................................................... 429 Operation of Simple Grading Mode.......................................................................................................... 429 Assist Control System......................................................................................................................... 431 Assist Control System Diagram............................................................................................................. 431 Function of Assist Control System......................................................................................................... 431 Operation of Assist Control System........................................................................................................ 432 Back Grade Mode System........................................................................................................................ 433 Back Grade Mode System Diagram............................................................................................................ 433 Function of Back Grade Mode System........................................................................................................ 434 Operation of Back Grade Mode System....................................................................................................... 434 Cut Control System............................................................................................................................ 435 Cut Control System Diagram................................................................................................................ 435 Function of Cut Control System............................................................................................................ 436 Operation of Cut Control System........................................................................................................... 436 Smooth Start System........................................................................................................................... 448 Smooth Start System Diagram............................................................................................................... 448 Function of Smooth Start System........................................................................................................... 448 Operation of Smooth Start System.......................................................................................................... 449 Slip Control System........................................................................................................................... 450 Slip Control System Diagram............................................................................................................... 450 Function of Slip Control System........................................................................................................... 451 Operation of Slip Control System.......................................................................................................... 451 Straight Travel Correction System............................................................................................................. 452 Straight Travel Correction System Diagram................................................................................................. 452 Function of Straight Travel Correction System............................................................................................. 453 Operation of Straight Travel Correction System............................................................................................ 453 Quick Surface Control System.................................................................................................................. 456 Quick Surface Control System Diagram...................................................................................................... 456 Function of Quick Surface Control System.................................................................................................. 456 Operation of Quick Surface Control System................................................................................................. 457 System of Triangulated Surface from AS-BUILT.................................................................................................. 458 System Diagram of Triangulated Surface from AS-BUILT...................................................................................... 458 Function of System of Triangulated Surface from AS-BUILT.................................................................................. 458 Operation of System of Triangulated Surface from AS-BUILT................................................................................. 458 2 Surfaces Selection Control System........................................................................................................... 460 2 Surfaces Selection Control System Diagram............................................................................................... 460 Function of 2 Surfaces Selection Control System........................................................................................... 461 Operation of 2 Surfaces Selection Control System.......................................................................................... 461 Lift Layer Control System..................................................................................................................... 462 Lift Layer Control System Diagram......................................................................................................... 462 Function of Lift Layer Control System..................................................................................................... 463 Operation of Lift Layer Control System.................................................................................................... 463 Component Parts of ICT System................................................................................................................. 464 ICT Sensor Controller..................................................................................................................... 464 Control Box............................................................................................................................... 468 GNSS Receiver............................................................................................................................. 470 GNSS Antenna.............................................................................................................................. 472 IMU Sensor................................................................................................................................ 473 Navigation Controller..................................................................................................................... 477 Cylinder EPC Valve Block Assembly......................................................................................................... 482 Stroke and Reset Sensor for Blade Lift Cylinder........................................................................................... 487 Undercarriage and Frame........................................................................................................................... 490 Main Frame.................................................................................................................................... 490 Structure of Main Frame................................................................................................................... 490 Suspension.................................................................................................................................... 492 Structure of Suspension................................................................................................................... 492 Specifications of Suspension.............................................................................................................. 493 Function of Suspension.................................................................................................................... 494 Track Frame and Idler Cushion................................................................................................................. 495 Structure of Track Frame and Idler Cushion................................................................................................ 495 Function of Track Frame and Idler Cushion................................................................................................. 497 Work Equipment.................................................................................................................................... 498 Structure of Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series).......................................................... 498 Structure of Fixed Multi-Shank Ripper......................................................................................................... 499 CAB Related Parts................................................................................................................................. 500 ROPS CAB...................................................................................................................................... 500 Structure of ROPS CAB..................................................................................................................... 500 Function of ROPS CAB...................................................................................................................... 501 CAB Mount..................................................................................................................................... 502 Structure of CAB Mount.................................................................................................................... 502 Function of CAB Mount..................................................................................................................... 502 20 Standard Value Table............................................................................................................................... 503 Table of Contents................................................................................................................................. 504 Standard Value Table for Engine................................................................................................................... 505 Standard Value Table for Engine: D65EXI-18E0.................................................................................................. 505 Standard Value Table for Engine: D65PXI-18E0.................................................................................................. 510 Standard Value Table for Machine.................................................................................................................. 515 Standard Value Table for Machine: D65EXI-18E0................................................................................................. 515 Standard Value Table for Machine: D65PXI-18E0................................................................................................. 531 Machine Posture and Procedures to Measure Performance......................................................................................... 546 30 Testing and Adjusting.............................................................................................................................. 549 Table of Contents................................................................................................................................. 550 Precautions Before Work........................................................................................................................... 554 Related Information on Testing and Adjusting...................................................................................................... 555 Differences In Machine Monitor Symbols........................................................................................................ 555 Tools for Testing and Adjusting............................................................................................................... 556 Sketch of Tools for Testing and Adjusting..................................................................................................... 564 Engine and Cooling System......................................................................................................................... 567 Examine Engine Speed.......................................................................................................................... 567 How to Examine Engine Speed............................................................................................................... 567 Examine Boost Pressure........................................................................................................................ 570 How to Examine Boost Pressure............................................................................................................. 570 Examine Exhaust Gas Temperature............................................................................................................... 572 How to Examine Exhaust Gas Temperature.................................................................................................... 572 Examine Exhaust Gas Color..................................................................................................................... 574 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................. 574 How to Examine Exhaust Gas Color with Smoke Meter......................................................................................... 574 Examine Mass Air Flow and Temperature Sensor.................................................................................................. 576 How to Examine Mass Air Flow and Temperature Sensor....................................................................................... 576 Examine and Adjust Valve Clearance............................................................................................................ 578 How to Examine Valve Clearance............................................................................................................ 578 How to Adjust Valve Clearance............................................................................................................. 579 Examine Compression Pressure.................................................................................................................. 581 How to Examine Compression Pressure....................................................................................................... 581 Examine Blowby Pressure....................................................................................................................... 583 How to Examine Blowby Pressure............................................................................................................ 583 Examine Engine Oil Pressure................................................................................................................... 586 How to Examine Engine Oil Pressure........................................................................................................ 586 Examine EGR Valve and VGT Oil Pressure........................................................................................................ 587 How to Examine EGR Valve and VGT Oil Pressure............................................................................................. 587 Examine Fuel Pressure......................................................................................................................... 589 How to Examine Fuel Pressure.............................................................................................................. 590 Examine Fuel Discharge, Return and Leakage.................................................................................................... 596 How to Examine Fuel Discharge, Return, and Leakage........................................................................................ 597 Bleed Air from Fuel System.................................................................................................................... 601 How to Bleed Air from Fuel System......................................................................................................... 601 Examine Fuel Circuit for Leakage.............................................................................................................. 603 How to Examine Fuel System for Leakage.................................................................................................... 603 Handle Cylinder Cut-out Mode Operation........................................................................................................ 605 Handle No-Injection Cranking Operation........................................................................................................ 606 Examine and Adjust Air Conditioner Compressor Belt Tension.................................................................................... 607 How to Examine Air Conditioner Compressor Belt Tension.................................................................................... 607 How to Adjust Air Conditioner Compressor Belt Tension..................................................................................... 607 Examine Alternator Belt....................................................................................................................... 608 How to Examine Alternator Belt............................................................................................................ 608 Examine Automatic Tensioner................................................................................................................... 610 How to Examine Automatic Tensioner........................................................................................................ 610 Write Correction for Ash in Soot Accumulation to Engine Controller............................................................................ 612 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................. 612 Examine SCR Related Functions................................................................................................................. 613 Examine DEF Pump Raised Pressure.......................................................................................................... 617 Examine Injection Volume from DEF Injector................................................................................................ 620 Examine DEF Line Heater Relay 1........................................................................................................... 625 Examine DEF Line Heater Relay 2........................................................................................................... 628 Examine DEF Pump Heater Relay............................................................................................................. 631 Examine DEF Tank Heater Valve............................................................................................................. 634 Examine SCR Denitration Efficiency........................................................................................................ 637 Clean DEF Tank................................................................................................................................ 640 How to Clean DEF Tank..................................................................................................................... 640 Clean DEF Tank Mounting Part.................................................................................................................. 644 How to Clean DEF Tank Mounting Part....................................................................................................... 644 Clean DEF Pump................................................................................................................................ 646 How to Clean DEF Pump..................................................................................................................... 646 Adjust Decelerator Pedal...................................................................................................................... 652 How to Adjust Decelerator Pedal........................................................................................................... 652 Power Train....................................................................................................................................... 654 Examine Power Train Oil Pressure.............................................................................................................. 654 How to Examine Power Train Oil Pressure................................................................................................... 655 Adjust Transmission Output Shaft Speed Sensor................................................................................................. 666 How to Adjust Transmission Output Shaft Speed Sensor...................................................................................... 666 Examine Brake Performance Simply.............................................................................................................. 668 How to Examine Brake Performance Simply................................................................................................... 668 Adjust Brake Pedal............................................................................................................................ 669 How to Adjust Brake Pedal................................................................................................................. 669 Adjust Parking Brake Lever.................................................................................................................... 671 How to Adjust Parking Brake Lever......................................................................................................... 671 Move Machine by Parking Brake Release When Machine Does Not Travel............................................................................ 673 How to Move Machine with Hydraulic Type Parking Brake Release System...................................................................... 673 How to Move Machine with Electric Type Parking Brake Release System....................................................................... 674 Undercarriage and Frame........................................................................................................................... 676 Adjust Idler Clearance........................................................................................................................ 676 How to Adjust Idler Clearance............................................................................................................. 676 Examine and Adjust Track Tension.............................................................................................................. 677 How to Examine Track Tension.............................................................................................................. 677 How to Adjust Track Tension............................................................................................................... 677 Hydraulic System.................................................................................................................................. 678 Release Remained Pressure in Hydraulic Circuit................................................................................................ 678 How to Release Remained Pressure in Hydraulic System...................................................................................... 678 Examine and Adjust Work Equipment and HSS Oil Pressure........................................................................................ 679 How to Examine Work Equipment and HSS Oil Pressure........................................................................................ 679 How to Adjust Oil Pressure of Work Equipment and HSS...................................................................................... 682 Examine Oil Pressure of Control Circuit....................................................................................................... 684 How to Examine Oil Pressure in Control Circuit............................................................................................ 684 Examine PPC Valve Outlet Pressure............................................................................................................. 686 How to Examine Outlet Pressure in PPC Valve............................................................................................... 686 Bleed Air from HSS Pump....................................................................................................................... 688 How to Bleed Air from HSS Pump............................................................................................................ 688 Examine and Adjust Play of Work Equipment PPC Valve........................................................................................... 689 How to Examine Play of Work Equipment PPC Valve........................................................................................... 689 How to Adjust Play of Work Equipment PPC Valve............................................................................................ 690 Examine Cooling Fan Speed..................................................................................................................... 691 How to Examine Cooling Fan Speed.......................................................................................................... 691 Examine Cooling Fan Circuit Oil Pressure...................................................................................................... 692 How to Examine Cooling Fan Circuit Oil Pressure........................................................................................... 692 Bleed Air in Cooling Fan Pump................................................................................................................. 694 How to Bleed Air in Cooling Fan Pump...................................................................................................... 694 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................................... 695 How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder................................................................... 695 How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder............................................................... 695 How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder.............................................................. 696 Examine Oil Leakage from Work Equipment Cylinder.............................................................................................. 697 How to Examine Internal Oil Leakage of Work Equipment Cylinder............................................................................ 697 Bleed Air from Work Equipment Cylinders....................................................................................................... 699 How to Bleed Air from Work Equipment Cylinder............................................................................................. 699 Work Equipment.................................................................................................................................... 700 Adjust Work Equipment Lock Lever.............................................................................................................. 700 How to Adjust Work Equipment Lock Lever................................................................................................... 700 CAB Related Parts................................................................................................................................. 702 Examine and Adjust Operator Cab............................................................................................................... 702 How to Examine Operator Cab............................................................................................................... 702 How to Adjust Operator Cab................................................................................................................ 704 Electrical System................................................................................................................................. 707 Set and Operate Machine Monitor............................................................................................................... 707 Operator Mode............................................................................................................................. 711 Function to Show Technician Identification Status Screen.................................................................................. 711 Function to Show Operator Identification Input Screen..................................................................................... 711 Examine Function by LCD (Liquid Crystal Display).......................................................................................... 712 Examine Function of Service Meter......................................................................................................... 712 How to Set Usage Limitation and Change Maintenance Password............................................................................... 712 Service Mode.............................................................................................................................. 715 How to Operate Service Mode............................................................................................................... 715 How to See Pre-defined Monitoring Information............................................................................................. 716 How to Examine Monitoring Information..................................................................................................... 722 Abnormality Record Menu................................................................................................................... 734 How to See Maintenance Record............................................................................................................. 738 Maintenance Mode Setting.................................................................................................................. 739 How to Set Phone Number Entry............................................................................................................. 743 Default Setting Menu...................................................................................................................... 745 Testing Menu.............................................................................................................................. 754 Adjustment Menu........................................................................................................................... 763 No-Injection Cranking Operation........................................................................................................... 818 KOMTRAX Settings Menu..................................................................................................................... 820 How to Show Service Message............................................................................................................... 822 How to Start Up KOMTRAX System................................................................................................................ 824 How to Stop Use of KOMTRAX System............................................................................................................. 829 Adjust When Power Train Controller is Replaced................................................................................................ 831 How to Adjust When Power Train Controller is Replaced..................................................................................... 831 Adjust Rearview Camera Angle.................................................................................................................. 834 How to Adjust Rearview Camera Angle....................................................................................................... 834 Set Region of Bluetooth(R) Compatible Radio................................................................................................... 835 How to Set Region of Bluetooth(R) Compatible Radio........................................................................................ 835 Handle Voltage Circuit of Engine Controller................................................................................................... 837 Handle Battery Disconnect Switch.............................................................................................................. 838 Examine Diodes................................................................................................................................ 839 How to Examine Diodes by Digital Tester................................................................................................... 839 How to Examine Diodes by Analog Tester.................................................................................................... 839 ICT System........................................................................................................................................ 840 Set and Operate Control Box................................................................................................................... 840 Examine and Adjust ICT Related Devices (SIGMA Power Tilt Pitch Dozer)..................................................................... 841 Examine and Adjust ICT Related Devices (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer).................................................... 845 Machine Calibration........................................................................................................................... 849 Calibrate IMU Sensor...................................................................................................................... 851 Operate Machine Calibration Step a (SIGMA Power Tilt Pitch Dozer)......................................................................... 856 Operate Machine Calibration Step a (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)........................................................ 861 Operate Machine Calibration Step B (SIGMA Power Tilt Pitch Dozer)......................................................................... 866 Operate Machine Calibration Step B (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)........................................................ 873 Calibrate GNSS Antenna (AUX) Location..................................................................................................... 880 Operate Pitch Rod Calibration (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)................................................................. 882 How to Input Wear Volume of Blade Edge and Track Shoes........................................................................................ 884 Reset Cylinder Stroke End..................................................................................................................... 885 Set Standard Blade Angle (SIGMA Power Tilt Pitch Dozer)....................................................................................... 887 How to Operate Manual Machine Calibration..................................................................................................... 889 Examine and Adjust Blade Elevation............................................................................................................ 891 How to Examine and Adjust Blade Elevation (SIGMA Power Tilt Pitch Dozer).................................................................. 891 How to Examine and Adjust Blade Elevation (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)................................................. 894 Examine Stroke Sensor for Lift Cylinder....................................................................................................... 898 How to Examine Stroke Sensor for Lift Cylinder............................................................................................ 898 Examine and Adjust Reset Sensor for Lift Cylinder............................................................................................. 902 How to Examine Reset Sensor for Lift Cylinder............................................................................................. 902 How to Adjust Reset Sensor for Lift Cylinder (SIGMA Power Tilt Pitch Dozer)............................................................... 903 How to Adjust Reset Sensor for Lift Cylinder (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer).............................................. 903 Adjust When ICT Sensor Controller is Replaced................................................................................................. 904 Adjust When ICT Sensor Controller is Replaced (SIGMA Power Tilt Pitch Dozer).............................................................. 904 Adjust When ICT Sensor Controller is Replaced (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)............................................. 906 Adjust After Replacement of IMU Sensor........................................................................................................ 909 How to Adjust After Replacement of IMU Sensor............................................................................................. 909 Adjust When ICT Related Devices are Repaired or Replaced (SIGMA Power Tilt Pitch Dozer)....................................................... 910 Adjust When ICT Related Devices are Repaired or Replaced (SIGMADOZER, Semi-U Dozer, Straight Tilt Dozer)...................................... 914 Pm Clinic......................................................................................................................................... 919 Pm Clinic Service............................................................................................................................. 919 Pm Clinic Check Sheet: D65EXI-18E0........................................................................................................ 921 Pm Clinic Check Sheet: D65PXI-18E0........................................................................................................ 932 Pm Clinic Check Sheet for Undercarriage: D65EXI-18E0...................................................................................... 942 Pm Clinic Check Sheet for Undercarriage: D65PXI-18E0...................................................................................... 945 40 Troubleshooting.................................................................................................................................... 949 Table of Contents................................................................................................................................. 950 Precautions Before Work........................................................................................................................... 962 Related Information to Troubleshooting............................................................................................................ 963 General Troubleshooting Points................................................................................................................ 963 Troubleshooting Points for Urea SCR System.................................................................................................... 964 Sequence of Events in Troubleshooting......................................................................................................... 978 Checks Before Troubleshooting................................................................................................................. 980 Inspection Procedure Before Troubleshooting................................................................................................... 982 Walk-Around Check......................................................................................................................... 982 Test in Accordance with Testing Procedure..................................................................................................... 984 How to Examine Electric Equipment......................................................................................................... 984 Preparation for Troubleshooting of Electrical System.......................................................................................... 992 Procedure for Troubleshooting................................................................................................................. 999 Symptom and Troubleshooting Numbers...........................................................................................................1002 Information Shown in Troubleshooting Table....................................................................................................1007 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness...............................................................1009 Connector List and Layout.....................................................................................................................1011 Connector Contact Connection Table............................................................................................................1031 T-Branch Box and T-Branch Adapter Table.......................................................................................................1071 Fuse Location Table...........................................................................................................................1077 Precautions When You Clean and Replace KDPF (KCSF and KDOC)...................................................................................1080 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])..........................................................1084 Failure Code Table............................................................................................................................1086 Troubleshooting by Failure Code (Display of Code).................................................................................................1109 Failure Code [1500L0].........................................................................................................................1109 Failure Code [15SAL1].........................................................................................................................1110 Failure Code [15SALH].........................................................................................................................1112 Failure Code [15SBL1].........................................................................................................................1114 Failure Code [15SBLH].........................................................................................................................1116 Failure Code [15SEL1].........................................................................................................................1118 Failure Code [15SELH].........................................................................................................................1120 Failure Code [15SFL1].........................................................................................................................1122 Failure Code [15SFLH].........................................................................................................................1124 Failure Code [15SGL1].........................................................................................................................1126 Failure Code [15SGLH].........................................................................................................................1128 Failure Code [15SJL1].........................................................................................................................1130 Failure Code [15SJLH].........................................................................................................................1132 Failure Code [1800MW].........................................................................................................................1134 Failure Code [879AKA].........................................................................................................................1135 Failure Code [879AKB].........................................................................................................................1136 Failure Code [879BKA].........................................................................................................................1137 Failure Code [879BKB].........................................................................................................................1139 Failure Code [879CKA].........................................................................................................................1141 Failure Code [879CKB].........................................................................................................................1142 Failure Code [879DKZ].........................................................................................................................1143 Failure Code [879EMC].........................................................................................................................1145 Failure Code [879FMC].........................................................................................................................1146 Failure Code [879GKX].........................................................................................................................1147 Failure Code [989L00].........................................................................................................................1149 Failure Code [989M00].........................................................................................................................1150 Failure Code [989N00].........................................................................................................................1151 Failure Code [A1U0N3].........................................................................................................................1152 Failure Code [A1U0N4].........................................................................................................................1154 Failure Code [A900FR].........................................................................................................................1156 Failure Code [A900N6].........................................................................................................................1157 Failure Code [A900NY].........................................................................................................................1158 Failure Code [AA10NX].........................................................................................................................1159 Failure Code [AB00KE].........................................................................................................................1161 Failure Code [AQ10N3].........................................................................................................................1163 Failure Code [AS00N3].........................................................................................................................1165 Failure Code [AS00R2].........................................................................................................................1167 Failure Code [AS00R3].........................................................................................................................1168 Failure Code [AS00R4].........................................................................................................................1169 Failure Code [AS00R5].........................................................................................................................1170 Failure Code [AS00R6].........................................................................................................................1171 Failure Code [AS00ZK].........................................................................................................................1172 Failure Code [AS10KM].........................................................................................................................1173 Failure Code [AS10NR].........................................................................................................................1174 Failure Code [AS10NT].........................................................................................................................1175 Failure Code [B@BAZG].........................................................................................................................1176 Failure Code [B@BCNS].........................................................................................................................1177 Failure Code [B@BCQA].........................................................................................................................1178 Failure Code [B@BCZK].........................................................................................................................1180 Failure Code [B@CENS].........................................................................................................................1182 Failure Code [B@HANS].........................................................................................................................1183 Failure Code [CA115]..........................................................................................................................1184 Failure Code [CA122]..........................................................................................................................1185 Failure Code [CA123]..........................................................................................................................1187 Failure Code [CA131]..........................................................................................................................1189 Failure Code [CA132]..........................................................................................................................1191 Failure Code [CA144]..........................................................................................................................1194 Failure Code [CA145]..........................................................................................................................1196 Failure Code [CA153]..........................................................................................................................1198 Failure Code [CA154]..........................................................................................................................1201 Failure Code [CA187]..........................................................................................................................1204 Failure Code [CA221]..........................................................................................................................1206 Failure Code [CA222]..........................................................................................................................1208 Failure Code [CA227]..........................................................................................................................1210 Failure Code [CA234]..........................................................................................................................1211 Failure Code [CA238]..........................................................................................................................1212 Failure Code [CA239]..........................................................................................................................1214 Failure Code [CA249]..........................................................................................................................1216 Failure Code [CA256]..........................................................................................................................1218 Failure Code [CA271]..........................................................................................................................1220 Failure Code [CA272]..........................................................................................................................1222 Failure Code [CA281]..........................................................................................................................1224 Failure Code [CA322]..........................................................................................................................1225 Failure Code [CA323]..........................................................................................................................1227 Failure Code [CA324]..........................................................................................................................1229 Failure Code [CA325]..........................................................................................................................1231 Failure Code [CA331]..........................................................................................................................1233 Failure Code [CA332]..........................................................................................................................1235 Failure Code [CA343]..........................................................................................................................1237 Failure Code [CA351]..........................................................................................................................1238 Failure Code [CA352]..........................................................................................................................1239 Failure Code [CA356]..........................................................................................................................1242 Failure Code [CA357]..........................................................................................................................1244 Failure Code [CA386]..........................................................................................................................1246 Failure Code [CA428]..........................................................................................................................1247 Failure Code [CA429]..........................................................................................................................1249 Failure Code [CA435]..........................................................................................................................1251 Failure Code [CA441]..........................................................................................................................1253 Failure Code [CA442]..........................................................................................................................1255 Failure Code [CA449]..........................................................................................................................1256 Failure Code [CA451]..........................................................................................................................1260 Failure Code [CA452]..........................................................................................................................1263 Failure Code [CA515]..........................................................................................................................1265 Failure Code [CA516]..........................................................................................................................1267 Failure Code [CA553]..........................................................................................................................1269 Failure Code [CA555]..........................................................................................................................1270 Failure Code [CA556]..........................................................................................................................1271 Failure Code [CA559]..........................................................................................................................1272 Failure Code [CA595]..........................................................................................................................1276 Failure Code [CA687]..........................................................................................................................1277 Failure Code [CA689]..........................................................................................................................1279 Failure Code [CA691]..........................................................................................................................1284 Failure Code [CA692]..........................................................................................................................1286 Failure Code [CA697]..........................................................................................................................1288 Failure Code [CA698]..........................................................................................................................1289 Failure Code [CA731]..........................................................................................................................1290 Failure Code [CA778]..........................................................................................................................1292 Failure Code [CA1117].........................................................................................................................1297 Failure Code [CA1664].........................................................................................................................1298 Failure Code [CA1669].........................................................................................................................1301 Failure Code [CA1673].........................................................................................................................1302 Failure Code [CA1677].........................................................................................................................1303 Failure Code [CA1678].........................................................................................................................1304 Failure Code [CA1682].........................................................................................................................1305 Failure Code [CA1683].........................................................................................................................1310 Failure Code [CA1684].........................................................................................................................1312 Failure Code [CA1686].........................................................................................................................1314 Failure Code [CA1691].........................................................................................................................1315 Failure Code [CA1694].........................................................................................................................1318 Failure Code [CA1695].........................................................................................................................1321 Failure Code [CA1696].........................................................................................................................1322 Failure Code [CA1712].........................................................................................................................1324 Failure Code [CA1713].........................................................................................................................1327 Failure Code [CA1714].........................................................................................................................1329 Failure Code [CA1715].........................................................................................................................1330 Failure Code [CA1776].........................................................................................................................1331 Failure Code [CA1777].........................................................................................................................1334 Failure Code [CA1843].........................................................................................................................1337 Failure Code [CA1844].........................................................................................................................1339 Failure Code [CA1879].........................................................................................................................1342 Failure Code [CA1881].........................................................................................................................1345 Failure Code [CA1883].........................................................................................................................1348 Failure Code [CA1885].........................................................................................................................1352 Failure Code [CA1887].........................................................................................................................1354 Failure Code [CA1921].........................................................................................................................1356 Failure Code [CA1922].........................................................................................................................1359 Failure Code [CA1942].........................................................................................................................1364 Failure Code [CA1993].........................................................................................................................1365 Failure Code [CA2185].........................................................................................................................1368 Failure Code [CA2186].........................................................................................................................1370 Failure Code [CA2249].........................................................................................................................1372 Failure Code [CA2265].........................................................................................................................1373 Failure Code [CA2266].........................................................................................................................1375 Failure Code [CA2271].........................................................................................................................1377 Failure Code [CA2272].........................................................................................................................1380 Failure Code [CA2311].........................................................................................................................1383 Failure Code [CA2349].........................................................................................................................1384 Failure Code [CA2353].........................................................................................................................1387 Failure Code [CA2357].........................................................................................................................1389 Failure Code [CA2381].........................................................................................................................1390 Failure Code [CA2382].........................................................................................................................1393 Failure Code [CA2383].........................................................................................................................1396 Failure Code [CA2386].........................................................................................................................1399 Failure Code [CA2387].........................................................................................................................1401 Troubleshooting Flowchart.................................................................................................................1405 Failure Code [CA2555].........................................................................................................................1406 Failure Code [CA2556].........................................................................................................................1409 Failure Code [CA2637].........................................................................................................................1412 Failure Code [CA2639].........................................................................................................................1414 Failure Code [CA2771].........................................................................................................................1417 Failure Code [CA2777].........................................................................................................................1423 Failure Code [CA2976].........................................................................................................................1426 Failure Code [CA3133].........................................................................................................................1428 Failure Code [CA3134].........................................................................................................................1430 Failure Code [CA3135].........................................................................................................................1432 Failure Code [CA3142].........................................................................................................................1436 Failure Code [CA3143].........................................................................................................................1437 Failure Code [CA3144].........................................................................................................................1438 Failure Code [CA3146].........................................................................................................................1440 Failure Code [CA3147].........................................................................................................................1441 Failure Code [CA3148].........................................................................................................................1442 Failure Code [CA3151].........................................................................................................................1444 Failure Code [CA3165].........................................................................................................................1450 Failure Code [CA3229].........................................................................................................................1452 Failure Code [CA3231].........................................................................................................................1454 Failure Code [CA3232].........................................................................................................................1456 Failure Code [CA3235].........................................................................................................................1460 Failure Code [CA3239].........................................................................................................................1462 Failure Code [CA3241].........................................................................................................................1465 Failure Code [CA3242].........................................................................................................................1468 Failure Code [CA3251].........................................................................................................................1471 Failure Code [CA3253].........................................................................................................................1473 Failure Code [CA3254].........................................................................................................................1476 Failure Code [CA3255].........................................................................................................................1479 Failure Code [CA3256].........................................................................................................................1482 Failure Code [CA3311].........................................................................................................................1484 Failure Code [CA3312].........................................................................................................................1486 Failure Code [CA3313].........................................................................................................................1489 Failure Code [CA3314].........................................................................................................................1490 Failure Code [CA3315].........................................................................................................................1491 Failure Code [CA3316].........................................................................................................................1494 Failure Code [CA3317].........................................................................................................................1495 Failure Code [CA3318].........................................................................................................................1496 Failure Code [CA3319].........................................................................................................................1499 Failure Code [CA3321].........................................................................................................................1500 Failure Code [CA3322].........................................................................................................................1502 Failure Code [CA3419].........................................................................................................................1505 Failure Code [CA3421].........................................................................................................................1507 Failure Code [CA3497].........................................................................................................................1509 Failure Code [CA3498].........................................................................................................................1510 Failure Code [CA3543].........................................................................................................................1511 Failure Code [CA3545].........................................................................................................................1518 Failure Code [CA3547].........................................................................................................................1520 Failure Code [CA3558].........................................................................................................................1521 Failure Code [CA3559].........................................................................................................................1523 Failure Code [CA3562].........................................................................................................................1525 Failure Code [CA3563].........................................................................................................................1527 Failure Code [CA3567].........................................................................................................................1530 Failure Code [CA3568].........................................................................................................................1533 Failure Code [CA3571].........................................................................................................................1539 Failure Code [CA3572].........................................................................................................................1541 Failure Code [CA3574].........................................................................................................................1543 Failure Code [CA3575].........................................................................................................................1546 Failure Code [CA3577].........................................................................................................................1548 Failure Code [CA3578].........................................................................................................................1550 Failure Code [CA3582].........................................................................................................................1552 Failure Code [CA3583].........................................................................................................................1561 Failure Code [CA3596].........................................................................................................................1563 Failure Code [CA3649].........................................................................................................................1566 Failure Code [CA3681].........................................................................................................................1568 Failure Code [CA3682].........................................................................................................................1570 Failure Code [CA3713].........................................................................................................................1573 Failure Code [CA3717].........................................................................................................................1576 Failure Code [CA3718].........................................................................................................................1577 Failure Code [CA3725].........................................................................................................................1578 Failure Code [CA3741].........................................................................................................................1581 Failure Code [CA3748].........................................................................................................................1582 Failure Code [CA3751].........................................................................................................................1585 Failure Code [CA3755].........................................................................................................................1587 Failure Code [CA3866].........................................................................................................................1589 Failure Code [CA3867].........................................................................................................................1593 Failure Code [CA3868].........................................................................................................................1596 Failure Code [CA3899].........................................................................................................................1600 Failure Code [CA3911].........................................................................................................................1602 Failure Code [CA3912].........................................................................................................................1606 Failure Code [CA3932].........................................................................................................................1608 Failure Code [CA3933].........................................................................................................................1610 Failure Code [CA3934].........................................................................................................................1612 Failure Code [CA3935].........................................................................................................................1615 Failure Code [CA3936].........................................................................................................................1617 Failure Code [CA4151].........................................................................................................................1619 Failure Code [CA4152].........................................................................................................................1623 Failure Code [CA4155].........................................................................................................................1627 Failure Code [CA4156].........................................................................................................................1630 Failure Code [CA4157].........................................................................................................................1633 Failure Code [CA4158].........................................................................................................................1635 Failure Code [CA4159].........................................................................................................................1636 Failure Code [CA4161].........................................................................................................................1637 Failure Code [CA4162].........................................................................................................................1640 Failure Code [CA4163].........................................................................................................................1643 Failure Code [CA4164].........................................................................................................................1645 Failure Code [CA4165].........................................................................................................................1647 Failure Code [CA4166].........................................................................................................................1649 Failure Code [CA4168].........................................................................................................................1651 Failure Code [CA4169].........................................................................................................................1654 Failure Code [CA4171].........................................................................................................................1656 Failure Code [CA4249].........................................................................................................................1659 Failure Code [CA4251].........................................................................................................................1661 Failure Code [CA4259].........................................................................................................................1663 Failure Code [CA4261].........................................................................................................................1666 Failure Code [CA4277].........................................................................................................................1669 Failure Code [CA4281].........................................................................................................................1673 Failure Code [CA4459].........................................................................................................................1677 Failure Code [CA4461].........................................................................................................................1680 Failure Code [CA4658].........................................................................................................................1683 Failure Code [CA4731].........................................................................................................................1687 Failure Code [CA4732].........................................................................................................................1688 Failure Code [CA4739].........................................................................................................................1689 Failure Code [CA4768].........................................................................................................................1690 Failure Code [CA4769].........................................................................................................................1692 Failure Code [CA4842].........................................................................................................................1695 Failure Code [CA4952].........................................................................................................................1699 Failure Code [CA5115].........................................................................................................................1701 Failure Code [CA5383].........................................................................................................................1704 Failure Code [D130KA].........................................................................................................................1706 Failure Code [D130KB].........................................................................................................................1709 Failure Code [D19DKA].........................................................................................................................1711 Failure Code [D19DKB].........................................................................................................................1713 Failure Code [D19JKZ].........................................................................................................................1715 Failure Code [D19UKA].........................................................................................................................1718 Failure Code [D19UKB].........................................................................................................................1720 Failure Code [D19UMC].........................................................................................................................1722 Failure Code [D811MC].........................................................................................................................1724 Failure Code [D862KA].........................................................................................................................1725 Failure Code [D8ALKA].........................................................................................................................1726 Failure Code [D8ALKB].........................................................................................................................1728 Failure Code [D8AQKR].........................................................................................................................1731 Failure Code [D8ARKR].........................................................................................................................1733 Failure Code [D8G1KT].........................................................................................................................1736 Failure Code [D8G6KT].........................................................................................................................1737 Failure Code [DAF0MB].........................................................................................................................1738 Failure Code [DAF0MC].........................................................................................................................1739 Failure Code [DAF8KB].........................................................................................................................1740 Failure Code [DAF9KQ].........................................................................................................................1741 Failure Code [DAFGMC].........................................................................................................................1742 Failure Code [DAFLKA].........................................................................................................................1743 Failure Code [DAFLKB].........................................................................................................................1745 Failure Code [DAFQKR].........................................................................................................................1748 Failure Code [DAQW00].........................................................................................................................1749 Failure Code [DAZ9KQ].........................................................................................................................1750 Failure Code [DAZQKR].........................................................................................................................1751 Failure Code [DB2QKR].........................................................................................................................1752 Failure Code [DB2RKR].........................................................................................................................1761 Failure Code [DBE0KT].........................................................................................................................1767 Failure Code [DBE0MC].........................................................................................................................1768 Failure Code [DBE1KK].........................................................................................................................1769 Failure Code [DBE2KK].........................................................................................................................1772 Failure Code [DBE2KT].........................................................................................................................1775 Failure Code [DBE5KK].........................................................................................................................1776 Failure Code [DBE6KK].........................................................................................................................1778 Failure Code [DBE7KK].........................................................................................................................1780 Failure Code [DBE9KQ].........................................................................................................................1782 Failure Code [DBELKA].........................................................................................................................1783 Failure Code [DBELKB].........................................................................................................................1785 Failure Code [DBEQKR].........................................................................................................................1787 Failure Code [DBERKR].........................................................................................................................1788 Failure Code [DBR0KT].........................................................................................................................1791 Failure Code [DBR0MC].........................................................................................................................1792 Failure Code [DBR1KK].........................................................................................................................1793 Failure Code [DBR2KK].........................................................................................................................1796 Failure Code [DBR2KT].........................................................................................................................1799 Failure Code [DBR5KK].........................................................................................................................1800 Failure Code [DBR7KK].........................................................................................................................1802 Failure Code [DBRLKA].........................................................................................................................1804 Failure Code [DBRLKB].........................................................................................................................1806 Failure Code [DBRPMA].........................................................................................................................1808 Failure Code [DBRQKR].........................................................................................................................1809 Failure Code [DBRRKR].........................................................................................................................1811 Failure Code [DBU0KR].........................................................................................................................1812 Failure Code [DBUSKR].........................................................................................................................1813 Failure Code [DBUTKA].........................................................................................................................1818 Failure Code [DBUTKN].........................................................................................................................1819 Failure Code [DBUTMA].........................................................................................................................1821 Failure Code [DBUUKA].........................................................................................................................1822 Failure Code [DBUUKN].........................................................................................................................1823 Failure Code [DD12KA].........................................................................................................................1825 Failure Code [DD12KB].........................................................................................................................1827 Failure Code [DD13KA].........................................................................................................................1829 Failure Code [DD13KB].........................................................................................................................1831 Failure Code [DD14KA].........................................................................................................................1833 Failure Code [DD14KB].........................................................................................................................1835 Failure Code [DDKHKA].........................................................................................................................1837 Failure Code [DDKHKB].........................................................................................................................1839 Failure Code [DDKQKA].........................................................................................................................1841 Failure Code [DDKQKB].........................................................................................................................1843 Failure Code [DDKRKA].........................................................................................................................1845 Failure Code [DDKRKB].........................................................................................................................1847 Failure Code [DDKSKA].........................................................................................................................1849 Failure Code [DDKSKB].........................................................................................................................1851 Failure Code [DDN7KA].........................................................................................................................1853 Failure Code [DDN7KB].........................................................................................................................1855 Failure Code [DDNLKA].........................................................................................................................1857 Failure Code [DDNLKB].........................................................................................................................1859 Failure Code [DGS1KA].........................................................................................................................1861 Failure Code [DGS1KX].........................................................................................................................1863 Failure Code [DGT1KA].........................................................................................................................1865 Failure Code [DGT1KX].........................................................................................................................1868 Failure Code [DH21KA].........................................................................................................................1870 Failure Code [DH21KY].........................................................................................................................1872 Failure Code [DHA4KA].........................................................................................................................1874 Failure Code [DHAAMA].........................................................................................................................1876 Failure Code [DHACMA].........................................................................................................................1878 Failure Code [DHSKKA].........................................................................................................................1880 Failure Code [DHSKKY].........................................................................................................................1882 Failure Code [DHSLKA].........................................................................................................................1884 Failure Code [DHSLKY].........................................................................................................................1886 Failure Code [DHSWKA].........................................................................................................................1888 Failure Code [DHSWKY].........................................................................................................................1890 Failure Code [DHSXKA].........................................................................................................................1892 Failure Code [DHSXKY].........................................................................................................................1894 Failure Code [DHTDKA].........................................................................................................................1896 Failure Code [DHTDKY].........................................................................................................................1898 Failure Code [DK10KA].........................................................................................................................1900 Failure Code [DK10KB].........................................................................................................................1903 Failure Code [DK30KA].........................................................................................................................1905 Failure Code [DK30KX].........................................................................................................................1908 Failure Code [DK30KY].........................................................................................................................1909 Failure Code [DK30KZ].........................................................................................................................1911 Failure Code [DK30L8].........................................................................................................................1912 Failure Code [DK31KA].........................................................................................................................1913 Failure Code [DK31KY].........................................................................................................................1916 Failure Code [DK40KA].........................................................................................................................1918 Failure Code [DK40KY].........................................................................................................................1920 Failure Code [DK55KX].........................................................................................................................1922 Failure Code [DK55KZ].........................................................................................................................1923 Failure Code [DK55L8].........................................................................................................................1924 Failure Code [DK56KA].........................................................................................................................1925 Failure Code [DK56KY].........................................................................................................................1927 Failure Code [DK57KA].........................................................................................................................1929 Failure Code [DK57KY].........................................................................................................................1931 Failure Code [DK80KR].........................................................................................................................1933 Failure Code [DK80KT].........................................................................................................................1936 Failure Code [DKH1KA].........................................................................................................................1938 Failure Code [DKH1KY].........................................................................................................................1941 Failure Code [DKSGL8].........................................................................................................................1943 Failure Code [DKSHKA].........................................................................................................................1944 Failure Code [DKSHKB].........................................................................................................................1946 Failure Code [DKSJKA].........................................................................................................................1948 Failure Code [DKSJKB].........................................................................................................................1950 Failure Code [DKSKKA].........................................................................................................................1952 Failure Code [DKSKKB].........................................................................................................................1954 Failure Code [DKSKMB].........................................................................................................................1956 Failure Code [DKSLL8].........................................................................................................................1958 Failure Code [DKSMKA].........................................................................................................................1959 Failure Code [DKSMKB].........................................................................................................................1961 Failure Code [DKSNKA].........................................................................................................................1963 Failure Code [DKSNKB].........................................................................................................................1965 Failure Code [DKSPKA].........................................................................................................................1967 Failure Code [DKSPKB].........................................................................................................................1969 Failure Code [DKSPMB].........................................................................................................................1971 Failure Code [DLM3KA].........................................................................................................................1973 Failure Code [DLM3MB].........................................................................................................................1975 Failure Code [DLT3KA].........................................................................................................................1976 Failure Code [DLT3KB].........................................................................................................................1978 Failure Code [DR21KX].........................................................................................................................1980 Failure Code [DR31KX].........................................................................................................................1981 Failure Code [DV20KB].........................................................................................................................1982 Failure Code [DW5AKA].........................................................................................................................1984 Failure Code [DW5AKB].........................................................................................................................1986 Failure Code [DW5AKY].........................................................................................................................1988 Failure Code [DW7BKA].........................................................................................................................1990 Failure Code [DW7BKB].........................................................................................................................1992 Failure Code [DW7BKY].........................................................................................................................1994 Failure Code [DWN1KA] (Applicable Machine: 96001 to 96603)....................................................................................1995 Failure Code [DWN1KA] (Applicable Machine: 96604 and Up)......................................................................................1997 Failure Code [DWN1KB] (Applicable Machine: 96001 to 96603)....................................................................................1999 Failure Code [DWN1KB] (Applicable Machine: 96604 and Up)......................................................................................2001 Failure Code [DWN1KY] (Applicable Machine: 96001 to 96603)....................................................................................2003 Failure Code [DWN1KY] (Applicable Machine: 96604 and Up)......................................................................................2005 Failure Code [DWN2KA] (Applicable Machine: 96001 to 96603)....................................................................................2007 Failure Code [DWN2KA] (Applicable Machine: 96604 and Up)......................................................................................2009 Failure Code [DWN2KB] (Applicable Machine: 96001 to 96603)....................................................................................2011 Failure Code [DWN2KB] (Applicable Machine: 96604 and Up)......................................................................................2013 Failure Code [DWN2KY] (Applicable Machine: 96001 to 96603)....................................................................................2015 Failure Code [DWN2KY] (Applicable Machine: 96604 and Up)......................................................................................2016 Failure Code [DWN5KA].........................................................................................................................2018 Failure Code [DWN5KB].........................................................................................................................2020 Failure Code [DWN5KY].........................................................................................................................2021 Failure Code [DXA2KA].........................................................................................................................2023 Failure Code [DXA2KB].........................................................................................................................2025 Failure Code [DXA2KY].........................................................................................................................2027 Failure Code [DXH1KA].........................................................................................................................2028 Failure Code [DXH1KB].........................................................................................................................2030 Failure Code [DXH1KY].........................................................................................................................2032 Failure Code [DXH4KA].........................................................................................................................2034 Failure Code [DXH4KB].........................................................................................................................2036 Failure Code [DXH4KY].........................................................................................................................2038 Failure Code [DXH5KA].........................................................................................................................2040 Failure Code [DXH5KB].........................................................................................................................2042 Failure Code [DXH5KY].........................................................................................................................2044 Failure Code [DXH6KA].........................................................................................................................2046 Failure Code [DXH6KB].........................................................................................................................2048 Failure Code [DXH6KY].........................................................................................................................2050 Failure Code [DXH7KA].........................................................................................................................2052 Failure Code [DXH7KB].........................................................................................................................2054 Failure Code [DXH7KY].........................................................................................................................2056 Failure Code [DXH8KA].........................................................................................................................2058 Failure Code [DXH8KB].........................................................................................................................2060 Failure Code [DXH8KY].........................................................................................................................2062 Failure Code [DXHRKA].........................................................................................................................2064 Failure Code [DXHRKB].........................................................................................................................2066 Failure Code [DXHRKY].........................................................................................................................2067 Failure Code [DXHSKA].........................................................................................................................2069 Failure Code [DXHSKB].........................................................................................................................2071 Failure Code [DXHSKY].........................................................................................................................2072 Failure Code [DXHTKA].........................................................................................................................2074 Failure Code [DXHTKB].........................................................................................................................2076 Failure Code [DXHTKY].........................................................................................................................2077 Failure Code [DXHUKA].........................................................................................................................2079 Failure Code [DXHUKB].........................................................................................................................2081 Failure Code [DXHUKY].........................................................................................................................2082 Failure Code [DXJ4KA].........................................................................................................................2084 Failure Code [DXJ4KB].........................................................................................................................2086 Failure Code [F311KA].........................................................................................................................2088 Failure Code [F311KB].........................................................................................................................2090 Failure Code [F312KA].........................................................................................................................2092 Failure Code [F312KB].........................................................................................................................2094 Failure Code [F313KA].........................................................................................................................2096 Failure Code [F313KB].........................................................................................................................2098 Failure Code [F314KA].........................................................................................................................2101 Failure Code [F314KB].........................................................................................................................2103 Failure Code [F315KB].........................................................................................................................2105 Failure Code [F315KY].........................................................................................................................2107 Failure Code [F316KB].........................................................................................................................2109 Failure Code [F316KY].........................................................................................................................2111 Failure Code [F318KB].........................................................................................................................2113 Failure Code [F318KY].........................................................................................................................2116 Failure Code [F31AKB].........................................................................................................................2118 Failure Code [F31AKY].........................................................................................................................2120 Failure Code [F31BKB].........................................................................................................................2122 Failure Code [F31BKY].........................................................................................................................2124 Failure Code [F31CKB].........................................................................................................................2126 Failure Code [F31CKY].........................................................................................................................2128 Failure Code [F31DKB].........................................................................................................................2130 Failure Code [F31DKY].........................................................................................................................2132 Failure Code [F31EKB].........................................................................................................................2134 Failure Code [F31EKY].........................................................................................................................2136 Failure Code [F7A0KQ].........................................................................................................................2138 Failure Code [F7A0KT].........................................................................................................................2139 Failure Code [F7A1KK].........................................................................................................................2140 Failure Code [F7ALKB].........................................................................................................................2143 Failure Code [F7AQKR].........................................................................................................................2145 Failure Code [F7ASKA].........................................................................................................................2146 Failure Code [FE0AKA].........................................................................................................................2148 Failure Code [FS10ZE].........................................................................................................................2150 Troubleshooting of Electrical System (E-Mode).....................................................................................................2151 Engine Does Not Start (Engine Does Not Crank).................................................................................................2151 Manual Preheating System Does Not Operate.....................................................................................................2158 Automatic Preheating System Does Not Operate..................................................................................................2161 While Preheating is in Operation, Preheating Monitor Does Not Come On.........................................................................2163 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing..................................................................2165 When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On.............................................2169 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation..................................................................2170 Charge Level Monitor Comes On in Red While Engine is in Operation.............................................................................2171 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation...............................................................2173 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation......................................................................2174 Power Train Oil Temperature Monitor Comes On in Red While Engine Runs.........................................................................2175 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation................................................................2176 Engine Coolant Temperature Gauge Does Not Show Correct Temperature............................................................................2177 DEF Level is Not Shown Correctly..............................................................................................................2178 Fuel Gauge Does Not Show Normally.............................................................................................................2181 Power Train Oil Temperature Gauge Does Not Show Correct Temperature...........................................................................2183 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature.............................................................................2184 Operation Mode Does Not Change................................................................................................................2185 Gear Shift Mode Does Not Change...............................................................................................................2186 When You Operate Customize Switch Does Not Show Customize Screen..............................................................................2187 When You Change Setting on Customize Screen, Setting of Machine is Not Changed................................................................2188 Some Areas of Machine Monitor Screen are Not Shown............................................................................................2189 REVERSE Slow Mode Function Does Not Operate Correctly.........................................................................................2190 Alarm Buzzer Does Not Operate or Does Not Stop Operation......................................................................................2191 Service Meter is Not Shown While Starting Switch is in OFF Position...........................................................................2192 Service Mode Cannot be Selected...............................................................................................................2193 Horn Does Not Sound...........................................................................................................................2194 Horn Does Not Stop............................................................................................................................2196 Backup Alarm Does Not Sound...................................................................................................................2197 Backup Alarm Does Not Stop Operation..........................................................................................................2199 Headlamp Does Not Come On.....................................................................................................................2200 Rear Lamp Does Not Come On....................................................................................................................2204 No Wiper Operates.............................................................................................................................2207 Front Wiper Does Not Operate..................................................................................................................2211 Rear Wiper Does Not Operate...................................................................................................................2214 Left Door Wiper Does Not Operate..............................................................................................................2217 Right Door Wiper Does Not Operate.............................................................................................................2220 Front Washer Does Not Operate.................................................................................................................2223 Rear Washer Does Not Operate..................................................................................................................2225 Left Door Washer Does Not Operate.............................................................................................................2227 Right Door Washer Does Not Operate............................................................................................................2229 KOMTRAX System Does Not Operate Correctly.....................................................................................................2231 Control Box Shows Message [Waiting for radio link...].........................................................................................2232 Control Box Shows Message [Waiting for satellites...].........................................................................................2234 Control Box Shows Message [GPS receiver not connected !] and [Komatsu Machine Trouble]........................................................2235 Control Box Shows Message [Komatsu Machine Trouble]...........................................................................................2236 Control Box Shows Message [Waiting to initialize...]..........................................................................................2237 Control Box Shows Message [System initializing]...............................................................................................2238 Control Box Shows Message [Initializing...]...................................................................................................2239 Control Box Shows Message [Connecting to GPS...]..............................................................................................2240 Elevation Control Key on Control Box Shows Message [Low precisions...]........................................................................2241 Control Box Shows Message [Heading Initializing]..............................................................................................2242 Control Box Shows Message [Out of design area...].............................................................................................2243 Control Box Shows Message [No GPS localization...]............................................................................................2244 Control Box Shows Message [Loading Design Surface data...]....................................................................................2245 Control Box Shows Message [Design Surface data invalid].......................................................................................2246 Control Box Shows Message [Starting switch is OFF]............................................................................................2247 Control Box Shows Message [Waiting for satellites...] and [Komatsu Machine Trouble]...........................................................2249 Control Box Shows Message [Blade Pitch Angle is Not Adjusted yet for Finish Work] (This Message is Not Deleted)...............................2250 Control Box Can Not be Turned on..............................................................................................................2252 Control Box Does Not Display Intelligent Machine Control Screen...............................................................................2253 Control Box Does Not Display Bulldozer Image..................................................................................................2254 Control Box Does Not Display Design Surface...................................................................................................2255 Control Box Touch Panel Does Not Respond......................................................................................................2256 Control Box Touch Panel is Inaccurate.........................................................................................................2257 Cylinder Stroke Reset Indication Does Not Go Out..............................................................................................2258 AUTO or Strikethrough is Not Shown When AUTO/Manual Switch is Pushed (AUTO or Strikethrough Goes Out).........................................2259 Blade Automatic Lower Control Does Not Start While AUTO is Shown..............................................................................2260 Blade Automatic Raise Control Does Not Start While AUTO is Shown..............................................................................2261 Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops).........................................2262 When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine...................................................2263 Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface)....2264 Finished Surface is Inaccurate (The Finished Surface is Not Smooth)...........................................................................2265 Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction).........................................2266 Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips).....................................2268 Blade Tilt Angle Does Not Align with Design Surface...........................................................................................2269 Blade Tilts While Blade Automatic Control is Activated........................................................................................2271 Even After Lift Layer Control is Activated, Measured Lift Layer Terrain Shape Does Not Agree with Actual Terrain..............................2273 The Surface Made with Quick Surface Creation Function is Different from the One in Machine Front Direction, Blade Edge Position...............2275 Machine Does Not Travel Straight While Tilt Steering Control is Activated.....................................................................2276 Control Box Continues to Show Progress Bar in Machine Manual Cal Screen.......................................................................2277 Engine Hunting Occurs When You Lower the Blade While Ground Line Assist is Activated..........................................................2278 In Cutting Operation, Work Equipment Pushes the Ground and Idlers Go Up from the Ground.......................................................2279 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).....................................................................................2280 Information Shown in Troubleshooting Table (H-Mode)...........................................................................................2280 System Chart of Hydraulic and Mechanical Systems..............................................................................................2281 Failure Mode and Cause Table..................................................................................................................2283 Machine Lacks Power (Drawbar Pull is Not Sufficient)..........................................................................................2291 Machine Does Not Travel (at 2nd or 3rd Gear Speed)............................................................................................2293 Machine Does Not Move Off at All Gear Speeds..................................................................................................2294 Machine Travels Only in One Direction, Forward or in Reverse..................................................................................2296 Large Time Lag is in Gear Shifting or Directional Change......................................................................................2297 Brake Does Not Work...........................................................................................................................2299 Power Train Oil Overheats.....................................................................................................................2300 Unusual Noise is Heard from Around Work Equipment and HSS Pump or HSS Motor...................................................................2302 Torque Converter Lockup Clutch Does Not Engage................................................................................................2303 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT)...............................................................................2304 Steering Speed or Power is Not Sufficient.....................................................................................................2305 All Work Equipment Operate Slowly.............................................................................................................2306 All Work Equipment Do Not Operate.............................................................................................................2307 Blade Lift Speed or Power is Low..............................................................................................................2308 Blade Tilt Speed or Power is Low..............................................................................................................2309 Blade Angle Speed or Power is Low.............................................................................................................2310 Ripper Lift Speed or Power is Low.............................................................................................................2311 Hydraulic Drift of Blade Lift is Large........................................................................................................2312 Hydraulic Drift of Tilted Blade is Large......................................................................................................2313 Hydraulic Drift of Lifted Ripper is Large.....................................................................................................2314 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...................................................................................2315 Unusual Noise is Heard from Around Fan........................................................................................................2317 Troubleshooting of Engine (S-Mode)................................................................................................................2318 Information Shown in Troubleshooting Table (S-Mode)...........................................................................................2318 Engine Does Not Crank When Starting Switch is Turned to Start Position........................................................................2319 Engine Cranks but No Exhaust Smoke Comes Out..................................................................................................2320 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).......................................................2321 Engine Startability is Unsatisfactory.........................................................................................................2323 Engine Does Not Pick Up Smoothly..............................................................................................................2325 Engine Stops During Operation.................................................................................................................2327 Engine Does Not Rotate Smoothly...............................................................................................................2329 Engine Lacks Output (or Lacks Power)..........................................................................................................2330 KDPF Becomes Clogged in a Short Time..........................................................................................................2332 Engine Oil Consumption is Excessive...........................................................................................................2334 Engine Oil Becomes Dirty Quickly..............................................................................................................2335 Fuel Consumption is Excessive.................................................................................................................2336 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down).........................................................................2337 Engine Oil Pressure Drops.....................................................................................................................2338 Fuel Mixes Into Engine Oil....................................................................................................................2340 Water Mixes Into Engine Oil (Milky)...........................................................................................................2341 Coolant Temperature Increases Too High (Overheat).............................................................................................2342 Unusual Noise is Heard........................................................................................................................2343 Vibration is Excessive........................................................................................................................2344 Air Cannot be Bled from Fuel Circuit..........................................................................................................2345 Active Regeneration is Done Frequently........................................................................................................2346 Active Regeneration Continues Long............................................................................................................2348 White Smoke is Exhausted During Active Regeneration...........................................................................................2349 DEF Consumption is Excessive..................................................................................................................2350 There is an Unusual Smell (Irritating Odor)...................................................................................................2352 Foreign Materials Enter DEF (DEF Increases)...................................................................................................2353 50 Disassembly and Assembly...........................................................................................................................2355 Table of Contents.................................................................................................................................2356 Precautions Before Work...........................................................................................................................2362 Related Information on Disassembly and Assembly...................................................................................................2363 How to Read This Manual.......................................................................................................................2363 Coating Materials List........................................................................................................................2364 Special Tool List.............................................................................................................................2369 Sketches of Special Tools.....................................................................................................................2391 Engine and Cooling System.........................................................................................................................2412 Remove and Install Supply Pump Assembly.......................................................................................................2412 How to Remove Supply Pump Assembly........................................................................................................2412 How to Install Supply Pump Assembly.......................................................................................................2416 Remove and Install Injector Assembly..........................................................................................................2421 How to Remove Injector Assembly...........................................................................................................2422 How to Install Injector Assembly..........................................................................................................2429 Remove and Install Cylinder Head Assembly.....................................................................................................2440 How to Remove Cylinder Head Assembly......................................................................................................2441 How to Install Cylinder Head Assembly.....................................................................................................2451 Remove and Install EGR Valve Assembly.........................................................................................................2467 How to Remove EGR Valve Assembly..........................................................................................................2467 How to Install EGR Valve Assembly.........................................................................................................2468 Remove and Install EGR Cooler Assembly........................................................................................................2469 How to Remove EGR Cooler Assembly.........................................................................................................2469 How to Install EGR Cooler Assembly........................................................................................................2470 Remove and Install Starter Assembly...........................................................................................................2472 How to Remove Starting Motor Assembly.....................................................................................................2472 How to Install Starting Motor Assembly....................................................................................................2474 Remove and Install Alternator Belt............................................................................................................2477 How to Remove Alternator Belt.............................................................................................................2477 How to Install Alternator Belt............................................................................................................2478 Remove and Install Automatic Tensioner........................................................................................................2480 How to Remove Automatic Tensioner.........................................................................................................2480 How to Install Automatic Tensioner........................................................................................................2480 Remove and Install Expansion Tank Assembly....................................................................................................2481 How to Remove Expansion Tank Assembly.....................................................................................................2481 How to Install Expansion Tank Assembly....................................................................................................2487 Remove and Install Radiator Assembly..........................................................................................................2494 How to Remove Radiator Assembly...........................................................................................................2494 How to Install Radiator Assembly..........................................................................................................2497 Remove and Install Hydraulic Oil Cooler Assembly..............................................................................................2502 How to Remove Hydraulic Oil Cooler Assembly...............................................................................................2502 How to Install Hydraulic Oil Cooler Assembly..............................................................................................2504 Remove and Install Aftercooler Assembly.......................................................................................................2508 How to Remove Aftercooler Assembly........................................................................................................2508 How to Install Aftercooler Assembly.......................................................................................................2510 Remove and Install Power Train Oil Cooler Assembly............................................................................................2513 How to Remove Power Train Oil Cooler Assembly.............................................................................................2513 How to Install Power Train Oil Cooler Assembly............................................................................................2515 Remove and Install Cooling Fan Drive Assembly.................................................................................................2518 How to Remove Cooling Fan Drive Assembly..................................................................................................2518 How to Install Cooling Fan Drive Assembly.................................................................................................2519 Remove and Install Cooling Fan Motor Assembly.................................................................................................2522 How to Remove Cooling Fan Motor Assembly..................................................................................................2522 How to Install Cooling Fan Motor Assembly.................................................................................................2524 Remove and Install Engine Assembly............................................................................................................2526 How to Remove Engine Assembly.............................................................................................................2526 How to Install Engine Assembly............................................................................................................2531 Remove and Install Engine Front Oil Seal......................................................................................................2538 How to Remove Engine Front Oil Seal.......................................................................................................2538 How to Install Engine Front Oil Seal......................................................................................................2540 Remove and Install Engine Rear Oil Seal.......................................................................................................2544 How to Remove Engine Rear Oil Seal........................................................................................................2544 How to Install Engine Rear Oil Seal.......................................................................................................2548 Remove and Install Engine Hood Assembly.......................................................................................................2556 How to Remove Engine Hood Assembly........................................................................................................2556 How to Install Engine Hood Assembly.......................................................................................................2562 Remove and Install Fuel Tank Assembly.........................................................................................................2569 How to Remove Fuel Tank Assembly..........................................................................................................2569 How to Install Fuel Tank Assembly.........................................................................................................2572 Remove and Install DEF Tank Assembly..........................................................................................................2575 How to Remove DEF Tank Assembly...........................................................................................................2576 How to Install DEF Tank Assembly..........................................................................................................2580 Remove and Install DEF Tank Sensor Flange Assembly............................................................................................2584 How to Remove DEF Tank Sensor Flange Assembly.............................................................................................2585 How to Install DEF Tank Sensor Flange Assembly............................................................................................2589 Remove and Install DEF Tank Sensor............................................................................................................2596 How to Remove DEF Tank Sensor.............................................................................................................2596 How to Install DEF Tank Sensor............................................................................................................2597 Remove and Install DEF Tank Strainer..........................................................................................................2604 How to Remove DEF Tank Strainer...........................................................................................................2604 How to Install DEF Tank Strainer..........................................................................................................2604 Remove and Install KDPF Assembly..............................................................................................................2605 How to Remove KDPF Assembly...............................................................................................................2605 How to Install KDPF Assembly..............................................................................................................2609 Disassemble and Assemble KDPF Assembly........................................................................................................2613 How to Disassemble KDPF Assembly..........................................................................................................2613 How to Assemble KDPF Assembly.............................................................................................................2617 Remove and Install SCR Assembly...............................................................................................................2623 How to Remove SCR Assembly................................................................................................................2623 How to Install SCR Assembly...............................................................................................................2625 Remove and Install KDPF and SCR Assembly......................................................................................................2628 How to Remove KDPF and SCR Assembly.......................................................................................................2628 How to Install KDPF and SCR Assembly......................................................................................................2635 Remove and Install KCCV Assembly..............................................................................................................2642 How to Remove KCCV Assembly...............................................................................................................2642 How to Install KCCV Assembly..............................................................................................................2644 Remove and Install DEF Mixing Tube............................................................................................................2646 How to Remove DEF Mixing Tube.............................................................................................................2646 How to Install DEF Mixing Tube............................................................................................................2649 Remove and Install DEF Injector...............................................................................................................2654 How to Remove DEF Injector................................................................................................................2654 How to Install DEF Injector...............................................................................................................2657 Remove and Install DEF Pump...................................................................................................................2661 How to Remove DEF Pump....................................................................................................................2661 How to Install DEF Pump...................................................................................................................2664 Remove and Install DEF Hose...................................................................................................................2667 How to Remove DEF Hose....................................................................................................................2667 How to Install DEF Hose...................................................................................................................2672 Remove and Install Air Cleaner Assembly.......................................................................................................2677 How to Remove Air Cleaner Assembly........................................................................................................2677 How to Install Air Cleaner Assembly.......................................................................................................2678 Remove and Install Air Conditioner Compressor Assembly........................................................................................2680 How to Remove Air Conditioner Compressor Assembly.........................................................................................2680 How to Install Air Conditioner Compressor Assembly........................................................................................2682 Remove and Install Air Conditioner Condenser Assembly.........................................................................................2685 How to Remove Air Conditioner Condenser Assembly..........................................................................................2685 How to Install Air Conditioner Condenser Assembly.........................................................................................2687 Power Train.......................................................................................................................................2689 Remove and Install Damper Assembly............................................................................................................2689 How to Remove Damper Assembly.............................................................................................................2689 How to Install Damper Assembly............................................................................................................2692 Remove and Install Power Train Unit Assembly..................................................................................................2697 How to Remove Power Train Unit Assembly...................................................................................................2697 How to Install Power Train Unit Assembly..................................................................................................2702 Disconnect and Connect Power Train Unit Assembly..............................................................................................2708 How to Disconnect Power Train Unit Assembly...............................................................................................2708 How to Connect Power Train Unit Assembly..................................................................................................2713 Disassemble and Assemble PTO Assembly.........................................................................................................2719 How to Disassemble PTO Assembly...........................................................................................................2719 How to Assemble PTO Assembly..............................................................................................................2722 Disassemble and Assemble Torque Converter Assembly............................................................................................2726 How to Disassemble Torque Converter Assembly..............................................................................................2727 How to Assemble Torque Converter Assembly.................................................................................................2733 Disassemble and Assemble Transmission Assembly................................................................................................2742 How to Disassemble Transmission Assembly..................................................................................................2743 How to Assemble Transmission Assembly.....................................................................................................2761 Disassemble and Assemble HSS Assembly.........................................................................................................2774 How to Disassemble HSS Assembly...........................................................................................................2776 How to Assemble HSS Assembly..............................................................................................................2787 Remove and Install HSS Motor Assembly.........................................................................................................2804 How to Remove HSS Motor Assembly..........................................................................................................2804 How to Install HSS Motor Assembly.........................................................................................................2806 Remove and Install Final Drive Assembly.......................................................................................................2809 How to Remove Final Drive Assembly........................................................................................................2809 How to Install Final Drive Assembly.......................................................................................................2812 Disassemble and Assemble Final Drive Assembly.................................................................................................2815 How to Disassemble Final Drive Assembly...................................................................................................2816 How to Assemble Final Drive Assembly......................................................................................................2821 Undercarriage and Frame...........................................................................................................................2829 Remove and Install Track Frame Assembly.......................................................................................................2829 How to Remove Track Frame Assembly........................................................................................................2829 How to Install Track Frame Assembly.......................................................................................................2832 Remove and Install Idler Assembly.............................................................................................................2836 How to Remove Idler Assembly..............................................................................................................2836 How to Install Idler Assembly.............................................................................................................2837 Disassemble and Assemble Idler Assembly.......................................................................................................2839 How to Disassemble Idler Assembly.........................................................................................................2839 How to Assemble Idler Assembly............................................................................................................2841 Remove and Install Recoil Spring Assembly.....................................................................................................2845 How to Remove Recoil Spring Assembly......................................................................................................2845 How to Install Recoil Spring Assembly.....................................................................................................2845 Disassemble and Assemble Recoil Spring Assembly...............................................................................................2847 How to Disassemble Recoil Spring Assembly.................................................................................................2847 How to Assemble Recoil Spring Assembly....................................................................................................2850 Remove and Install Track Roller Assembly......................................................................................................2853 How to Remove Track Roller Assembly.......................................................................................................2853 How to Install Track Roller Assembly......................................................................................................2854 Disassemble and Assemble Track Roller Assembly................................................................................................2855 How to Disassemble Track Roller Assembly..................................................................................................2855 How to Assemble Track Roller Assembly.....................................................................................................2857 Remove and Install Carrier Roller Assembly....................................................................................................2860 How to Remove Carrier Roller Assembly.....................................................................................................2860 How to Install Carrier Roller Assembly....................................................................................................2861 Disassemble and Assemble Carrier Roller Assembly..............................................................................................2862 How to Disassemble Carrier Roller Assembly................................................................................................2862 How to Assemble Carrier Roller Assembly...................................................................................................2863 Remove and Install Pivot Shaft Assembly.......................................................................................................2866 How to Remove Pivot Shaft Assembly........................................................................................................2866 How to Install Pivot Shaft Assembly.......................................................................................................2867 Separate and Connect PLUS Type Track Assembly.................................................................................................2868 Separate PLUS Type Track Assembly Generally...............................................................................................2868 Install PLUS Type Track Assembly..........................................................................................................2868 Disassemble and Assemble Track Assembly Generally.............................................................................................2869 How to Disassemble Full Track Shoes Assembly..............................................................................................2869 How to Assemble Full Track Shoes Assembly.................................................................................................2872 Disassemble and Assemble PLUS Type Track Assembly Generally...................................................................................2884 Disassemble PLUS Type Track Assembly Generally............................................................................................2885 How to Assemble PLUS Type Track Shoes Assembly Generally..................................................................................2886 Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)....................................................................2901 How to Disassemble One Track Link Assembly in Field (Track Assembly)......................................................................2902 How to Assemble One Track Link Assembly in Field (Track Assembly).........................................................................2903 Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)..........................................................2910 Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly)...................................................................2911 Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)......................................................................2913 Remove and Install Equalizer Bar Assembly.....................................................................................................2917 How to Remove Equalizer Bar Assembly......................................................................................................2917 How to Install Equalizer Bar Assembly.....................................................................................................2919 Disassemble and Assemble Equalizer Bar Bushing................................................................................................2922 How to Disassemble Equalizer Bar Bushing..................................................................................................2922 How to Assemble Equalizer Bar Bushing.....................................................................................................2922 Hydraulic System..................................................................................................................................2924 Remove and Install Hydraulic Tank Assembly....................................................................................................2924 How to Remove Hydraulic Tank Assembly.....................................................................................................2924 How to Install Hydraulic Tank Assembly....................................................................................................2927 Remove and Install HSS Pump and Cooling Fan Pump Assembly.....................................................................................2932 How to Remove HSS Pump and Cooling Fan Pump Assembly......................................................................................2932 How to Install HSS Pump and Cooling Fan Pump Assembly.....................................................................................2933 Remove and Install Power Train Pump and Steering Lubrication Pump Assembly....................................................................2936 How to Remove Power Train Pump and Steering Lubrication Pump Assembly.....................................................................2936 How to Install Power Train Pump and Steering Lubrication Pump Assembly....................................................................2938 Remove and Install Scavenging Pump Assembly...................................................................................................2941 How to Remove Scavenging Pump Assembly....................................................................................................2941 How to Install Scavenging Pump Assembly...................................................................................................2941 Remove and Install 5 Spool Control Valve Assembly.............................................................................................2943 How to Remove 5 Spool Control Valve Assembly..............................................................................................2943 How to Install 5 Spool Control Valve Assembly.............................................................................................2945 Remove and Install 4 Spool Control Valve Assembly.............................................................................................2948 How to Remove 4 Spool Control Valve Assembly..............................................................................................2948 How to Install 4 Spool Control Valve Assembly.............................................................................................2951 Disassemble and Assemble Blade PPC Valve......................................................................................................2954 How to Disassemble Blade PPC Valve........................................................................................................2954 How to Assemble Blade PPC Valve...........................................................................................................2954 Disassemble and Assemble Ripper PPC Valve.....................................................................................................2956 How to Disassemble Ripper PPC Valve.......................................................................................................2956 How to Assemble Ripper PPC Valve..........................................................................................................2956 Work Equipment....................................................................................................................................2958 Remove and Install Straight Tilt Power Pitch Dozer Blade Assembly.............................................................................2958 How to Remove Straight Tilt Power Pitch Dozer Blade Assembly..............................................................................2958 How to Install Straight Tilt Power Pitch Dozer Blade Assembly.............................................................................2960 Remove and Install Ripper Assembly............................................................................................................2964 How to Remove Ripper Assembly.............................................................................................................2964 How to Install Ripper Assembly............................................................................................................2967 Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series)...................................2970 How to Remove Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series)....................................2970 How to Remove and Install Stroke Sensing Blade Lift Cylinder Assembly (For Straight Tilt Power Pitch Dozer Series)........................2972 Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly................................................................2976 How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly..................................................................2977 Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly............................................................................2983 CAB Related Parts.................................................................................................................................2996 Remove and Install Operator Cab Assembly......................................................................................................2996 How to Remove Operator Cab Assembly.......................................................................................................2996 How to Install Operator Cab Assembly......................................................................................................3005 Remove and Install Operator Cab Glass (Adhered Glass).........................................................................................3015 How to Remove Operator Cab Glass (Adhered Glass)..........................................................................................3015 How to Install Operator Cab Glass (Adhered Glass).........................................................................................3016 Remove and Install Air Conditioner Unit Assembly..............................................................................................3021 How to Remove Air Conditioner Unit Assembly...............................................................................................3021 How to Install Air Conditioner Unit Assembly..............................................................................................3028 Remove and Install Operator Seat..............................................................................................................3037 How to Remove Operator Seat...............................................................................................................3037 How to Install Operator Seat..............................................................................................................3039 How to Remove and Install Seat Belt...........................................................................................................3042 How to Remove Seat Belt...................................................................................................................3042 How to Install Seatbelt...................................................................................................................3043 Electrical System.................................................................................................................................3044 Remove and Install Engine Controller Assembly.................................................................................................3044 How to Remove Engine Controller Assembly..................................................................................................3044 How to Install Engine Controller Assembly.................................................................................................3045 Remove and Install Power Train Controller Assembly............................................................................................3048 How to Remove Power Train Controller Assembly.............................................................................................3048 How to Install Power Train Controller Assembly............................................................................................3049 Remove and Install Machine Monitor Assembly...................................................................................................3051 How to Remove Machine Monitor Assembly....................................................................................................3051 How to Install Machine Monitor Assembly...................................................................................................3052 Remove and Install Mass Air Flow and Temperature Sensor.......................................................................................3054 How to Remove Mass Air Flow and Temperature Sensor........................................................................................3054 How to Install Mass Air Flow and Temperature Sensor.......................................................................................3055 Remove and Install KCCV Crankcase Pressure Sensor.............................................................................................3056 How to Remove KCCV Crankcase Pressure Sensor..............................................................................................3056 How to Install KCCV Crankcase Pressure Sensor.............................................................................................3057 Remove and Install SCR Temperature Sensor.....................................................................................................3058 How to Remove SCR Temperature Sensor......................................................................................................3058 How to Install SCR Temperature Sensor.....................................................................................................3059 Remove and Install Rearview Camera............................................................................................................3061 How to Remove Rearview Camera.............................................................................................................3061 How to Install Rearview Camera............................................................................................................3061 Remove and Install Gateway Function Controller Assembly.......................................................................................3063 How to Remove Gateway Function Controller Assembly........................................................................................3063 How to Install Gateway Function Controller Assembly.......................................................................................3066 Remove and Install Communication Terminal.....................................................................................................3071 How to Remove Communication Terminal......................................................................................................3071 How to Install Communication Terminal.....................................................................................................3074 Remove and Install ICT Sensor Controller Assembly.............................................................................................3077 How to Remove ICT Sensor Controller Assembly..............................................................................................3077 How to Install ICT Sensor Controller Assembly.............................................................................................3077 Remove and Install Navigation Controller......................................................................................................3079 How to Remove Navigation Controller.......................................................................................................3079 How to Install Navigation Controller......................................................................................................3083 Remove and Install Control Box................................................................................................................3089 How to Remove Control Box.................................................................................................................3089 How to Install Control Box................................................................................................................3090 Remove and Install GNSS Receiver..............................................................................................................3091 How to Remove GNSS Receiver...............................................................................................................3091 How to Install GNSS Receiver..............................................................................................................3092 Remove and Install GNSS Antenna...............................................................................................................3094 How to Remove GNSS Antenna................................................................................................................3095 How to Install GNSS Antenna...............................................................................................................3097 Remove and Install IMU Sensor.................................................................................................................3103 How to Remove IMU Sensor..................................................................................................................3103 How to Install IMU Sensor.................................................................................................................3105 60 Maintenance Standard...............................................................................................................................3109 Table of Contents.................................................................................................................................3110 Explanation of Terms for Maintenance Standard.....................................................................................................3112 Engine and Cooling System.........................................................................................................................3114 Maintenance Standard for Engine Mount.........................................................................................................3114 Maintenance Standard for Damper...............................................................................................................3115 Maintenance Standard for Cooling System.......................................................................................................3117 Maintenance Standard for Cooling Fan Pump.....................................................................................................3119 Maintenance Standard for Servo Valve......................................................................................................3120 Maintenance Standard for Cooling Fan Motor....................................................................................................3121 Power Train.......................................................................................................................................3123 Maintenance Standard for Universal Joint......................................................................................................3123 Maintenance Standard for Power Train Mount....................................................................................................3124 Maintenance Standard for Torque Converter and PTO.............................................................................................3126 Maintenance Standard for Lockup Clutch ECMV...................................................................................................3129 Maintenance Standard for Transmission.........................................................................................................3130 Maintenance Standard for Transmission Control Valve...........................................................................................3135 Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV...........................................................3136 Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve..................................................................3137 Maintenance Standard for Transmission Lubrication Relief Valve................................................................................3138 Maintenance Standard for Bevel Gear Shaft, HSS, and Brake.....................................................................................3139 Maintenance Standard for Brake Valve..........................................................................................................3144 Maintenance Standard for Final Drive..........................................................................................................3146 Maintenance Standard for Sprocket for Conventional Type Track Shoes...........................................................................3148 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes..........................................3149 Maintenance Standard for Sprocket for PLUS Type Track Shoes...................................................................................3151 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes..................................................3152 Undercarriage and Frame...........................................................................................................................3154 Maintenance Standard for Main Frame...........................................................................................................3154 Maintenance Standard for Suspension...........................................................................................................3155 Maintenance Standard for Track Frame and Idler Cushion........................................................................................3157 Maintenance Standard for Idler................................................................................................................3159 Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type)..................................................3161 Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type)..................................................3162 Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)..........................................................3163 Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)..........................................................3164 Maintenance Standard for Carrier Roller for Conventional Type Track Shoes.....................................................................3165 Maintenance Standard for Carrier Roller for PLUS Type Track Shoes.............................................................................3166 Maintenance Standard for Conventional Type Track Shoes........................................................................................3167 Maintenance Standard for PLUS Type Track Shoes................................................................................................3169 Maintenance Standard for Single Shoes.........................................................................................................3171 Maintenance Standard for Swamp Shoes..........................................................................................................3172 Hydraulic System..................................................................................................................................3173 Maintenance Standard for Hydraulic Tank.......................................................................................................3173 Maintenance Standard for Scavenging Pump......................................................................................................3174 Maintenance Standard for Steering Lubrication Pump and Power Train Pump.......................................................................3175 Maintenance Standard for Work Equipment and HSS Pump..........................................................................................3176 Maintenance Standard for PC-EPC Valve.........................................................................................................3177 Maintenance Standard for HSS Motor............................................................................................................3178 Maintenance Standard for Control Valve........................................................................................................3180 Maintenance Standard for Blade PPC Valve......................................................................................................3188 Maintenance Standard for Ripper PPC Valve.....................................................................................................3190 Maintenance Standard for Quick Drop Valve.....................................................................................................3192 Maintenance Standard for Work Equipment Lock Solenoid Valve (For Tilt Dozer Series)...........................................................3194 Maintenance Standard for Work Equipment Lock Solenoid Valve (For Power Tilt Pitch Dozer Series)...............................................3195 Work Equipment....................................................................................................................................3196 Maintenance Standard for Front Work Equipment (For Tilt Dozer and Power Tilt Pitch Dozer Series)..............................................3196 Maintenance Standard for Cutting Edge and End Bit.............................................................................................3199 Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series)......................3201 Maintenance Standard for Blade Tilt Cylinder (For Tilt Dozer and Power Tilt Pitch Dozer Series)...............................................3202 Maintenance Standard for Blade Pitch Cylinder (For Power Tilt Pitch Dozer Series).............................................................3203 Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder (Tilt Dozer, Semi-U Dozer, Power Tilt Pitch Dozer Series)............3204 Maintenance Standard for Fixed Multi-Shank Ripper.............................................................................................3206 Maintenance Standard for Ripper Lift Cylinder.................................................................................................3207 CAB Related Parts.................................................................................................................................3208 Maintenance Standard for CAB Mount............................................................................................................3208 80 Appendix...........................................................................................................................................3209 Table of Contents.................................................................................................................................3210 Precautions Before Work...........................................................................................................................3212 Air Conditioner System............................................................................................................................3213 Precautions for Refrigerant...................................................................................................................3213 Air Conditioner Component.....................................................................................................................3214 Specifications of Air Conditioner.............................................................................................................3216 Structure and Function of Refrigeration Cycle.................................................................................................3217 Outline of Refrigeration Cycle................................................................................................................3218 Component Parts of Air Conditioner System.........................................................................................................3220 Air Conditioner Unit..........................................................................................................................3220 Configuration Diagram of Air Conditioner Unit.............................................................................................3220 Function of Air Conditioner Unit..........................................................................................................3222 Component Parts of Air Conditioner Unit.......................................................................................................3224 Function of Evaporator as Air Conditioner Unit Component..................................................................................3225 Function of Heater Core as Air Conditioner Unit Component.................................................................................3225 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component...............................................................3225 Function of Servo Motor as Air Conditioner Unit Component.................................................................................3225 Structure of Expansion Valve as Air Conditioner Unit Component............................................................................3226 Function of Expansion Valve as Air Conditioner Unit Component.............................................................................3226 Operate Expansion Valve as Air Conditioner Unit Component.................................................................................3226 Function of Dual Pressure Switch..........................................................................................................3227 Air Conditioner Controller....................................................................................................................3228 Structure of Air Conditioner Controller...................................................................................................3228 Compressor....................................................................................................................................3229 Structure of Compressor...................................................................................................................3229 Specifications of Compressor..............................................................................................................3229 Function of Compressor....................................................................................................................3229 Condenser.....................................................................................................................................3230 Structure of Standard Core Condenser......................................................................................................3230 Specifications of Standard Core Condenser.................................................................................................3230 Function of Standard Core Condenser.......................................................................................................3230 Structure of Wide Core Condenser..........................................................................................................3231 Specifications of Wide Core Condenser.....................................................................................................3231 Function of Wide Core Condenser...........................................................................................................3231 Receiver Drier................................................................................................................................3232 Structure of Receiver Dryer...............................................................................................................3232 Specifications of Receiver Dryer..........................................................................................................3232 Function of Receiver Dryer................................................................................................................3232 Air Conditioner Related Sensors...............................................................................................................3233 Structure of Sunlight Sensor..............................................................................................................3233 Function of Sunlight Sensor...............................................................................................................3233 Structure of Outside Temperature Sensor...................................................................................................3233 Function of Outside Air Temperature Sensor................................................................................................3233 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.......................................................................3235 Circuit Diagram and Configuration of Connector Pins of Air Conditioner............................................................................3237 System Diagram of Air Conditioner.................................................................................................................3239 Input and Output Signals of Air Conditioner Controller........................................................................................3240 Function of Air Conditioner Controller....................................................................................................3241 Locations of Air Conditioner Parts and Layout of Connectors.......................................................................................3242 Examine Air Leakage (Duct)........................................................................................................................3251 How to Examine Air Leakage (Duct).............................................................................................................3251 Explanation for Test of Air Conditioner with Self-Diagnosis Function..............................................................................3254 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor...........................................................3255 Examine Vent (Mode) Changeover....................................................................................................................3256 How to Examine Vent (Mode) Changeover.........................................................................................................3256 Examine Fresh/Recirc Air Changeover...............................................................................................................3257 How to Examine Fresh/Recirc Air Changeover....................................................................................................3257 Examine Sunlight Sensor...........................................................................................................................3258 How to Examine Sunlight Sensor................................................................................................................3258 Examine Refrigerant (Dual) Pressure Switch........................................................................................................3259 How to Examine Refrigerant (Dual) Pressure Switch.............................................................................................3259 Examine Relay.....................................................................................................................................3260 How to Examine Relay..........................................................................................................................3260 Air Conditioner Troubleshooting Chart 1...........................................................................................................3261 Air Conditioner Troubleshooting Chart 2...........................................................................................................3262 Information Shown in Troubleshooting Table........................................................................................................3265 Failure Code [879AKA].............................................................................................................................3266 Failure Code [879AKB].............................................................................................................................3267 Failure Code [879BKA].............................................................................................................................3268 Failure Code [879BKB].............................................................................................................................3270 Failure Code [879CKA].............................................................................................................................3272 Failure Code [879CKB].............................................................................................................................3273 Failure Code [879DKZ].............................................................................................................................3274 Failure Code [879EMC].............................................................................................................................3276 Failure Code [879FMC].............................................................................................................................3277 Failure Code [879GKX].............................................................................................................................3278 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)........................................................................3280 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled).........................................................................3282 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)................................................................3286 Troubleshooting for Fresh/Recirc Air Changeover...................................................................................................3288 Troubleshooting by Gauge Pressure.................................................................................................................3290 Connect Service Tool..............................................................................................................................3293 How to Connect Service Tool...................................................................................................................3293 Precautions for Disconnection and Connection of Air Conditioner Piping............................................................................3295 Handle Compressor Oil.............................................................................................................................3297 90 Circuit Diagrams...................................................................................................................................3299 Table of Contents.................................................................................................................................3300 How to Read the Codes for Electric Cable..........................................................................................................3301 Hydraulic Circuit Diagram.........................................................................................................................3305 Symbols Used in Hydraulic Circuit Diagram.....................................................................................................3305 Hydraulic Circuit Diagram (For Tilt Dozer Series).............................................................................................3309 Hydraulic Circuit Diagram (For Power Tilt Pitch Dozer Series).................................................................................3311 Power Train Hydraulic Circuit Diagram.........................................................................................................3313 Electrical Circuit Diagram........................................................................................................................3315 Symbols Used in Electric Circuit Diagram......................................................................................................3315 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (1/18)........................................................................3319 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (2/18)........................................................................3321 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (3/18)........................................................................3323 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (4/18)........................................................................3325 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (5/18)........................................................................3327 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (6/18)........................................................................3329 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (7/18)........................................................................3331 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (8/18)........................................................................3333 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (9/18)........................................................................3335 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (10/18).......................................................................3337 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (11/18).......................................................................3339 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (12/18).......................................................................3341 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (13/18).......................................................................3343 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (14/18).......................................................................3345 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (15/18).......................................................................3347 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (16/18).......................................................................3349 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (17/18).......................................................................3351 Electrical Circuit Diagram (Applicable Machine: 96001 to 96603) (18/18).......................................................................3353 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (1/18)..........................................................................3355 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (2/18)..........................................................................3357 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (3/18)..........................................................................3359 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (4/18)..........................................................................3361 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (5/18)..........................................................................3363 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (6/18)..........................................................................3365 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (7/18)..........................................................................3367 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (8/18)..........................................................................3369 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (9/18)..........................................................................3371 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (10/18).........................................................................3373 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (11/18).........................................................................3375 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (12/18).........................................................................3377 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (13/18).........................................................................3379 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (14/18).........................................................................3381 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (15/18).........................................................................3383 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (16/18).........................................................................3385 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (17/18).........................................................................3387 Electrical Circuit Diagram (Applicable Machine: 96604 and Up) (18/18).........................................................................3389 Index..................................................................................................................................................3391
DESCRIPTION:
KOMATSU D65EXi-18E0 D65PXi-18E0 BULLDOZER SHOP MANUAL SEN06898-05 – PDF DOWNLOAD
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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual
S.S 28/12/24
