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KOMATSU D85EX-15 D85PX-15 SERVICE REPAIR MANUAL (SN:10001 & UP) (SN:1001 & UP ) – PDF Download
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- KOMATSU D85EX-15 D85PX-15 SERVICE REPAIR MANUAL (SN:10001 & UP) (SN:1001 & UP )
- PUBLICATION NUMBER:SEBM029108
- SERIAL NUMBER:
D85EX-15 10001 and up
D85PX-15 1001 and up
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KOMATSU D85EX-15 D85PX-15 SERVICE REPAIR MANUAL (SN:10001 & UP) (SN:1001 & UP )
KOMATSU D85EX-15 D85PX-15 SERVICE REPAIR MANUAL (SN:10001 & UP) (SN:1001 & UP ) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D85EX-15 D85PX-15 SERVICE REPAIR MANUAL (SN:10001 & UP) (SN:1001 & UP )
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU D85EX-15 D85PX-15 SERVICE REPAIR MANUAL (SN:10001 & UP) (SN:1001 & UP )
COVER ........................................................................................................................................ 1 CONTENTS...................................................................................................................................... 2 01 GENERAL.................................................................................................................................... 27 SPECIFICATION DRAWING..................................................................................................................... 28 SPECIFICATIONS............................................................................................................................ 30 WEIGHT TABLE.............................................................................................................................. 41 TABLE OF FULE, COOLANT AND LUBRICANT...................................................................................................... 43 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................................................................... 45 POWER TRAIN............................................................................................................................... 46 OVERALL DRAWING OF POWER TRAIN UNIT....................................................................................................... 48 HYDRAULIC PIPING OF POWER TRAIN .......................................................................................................... 50 DAMPER, UNIVERSAL JOINT .................................................................................................................. 51 TORQUE CONVERTER, PTO..................................................................................................................... 53 SCAVENGING PUMP........................................................................................................................... 59 TRANSMISSION CONTROL...................................................................................................................... 60 TRANSMISSION.............................................................................................................................. 61 TRANSMISSION ECMV......................................................................................................................... 73 MAIN RELIEF VALVE......................................................................................................................... 78 LUBRICATION RELIEF VALVE ................................................................................................................. 80 POWER TRAIN PUMP, LUBRICATION PUMP........................................................................................................ 81 HSS SYSTEM................................................................................................................................ 82 HYDRAULIC, HSS PUMP....................................................................................................................... 84 HSS MOTOR.................................................................................................................................102 HSS OIL COOLER BYPASS VALVE ..............................................................................................................109 STEERING, BRAKE CONTROL...................................................................................................................110 BEVEL GEAR SHAFT, HSS, BRAKE..............................................................................................................112 BRAKE VALVE...............................................................................................................................126 FINAL DRIVE...............................................................................................................................131 SPROCKET..................................................................................................................................138 TRACK FRAME...............................................................................................................................140 RECOIL SPRING.............................................................................................................................142 IDLER.....................................................................................................................................144 TRACK ROLLER..............................................................................................................................146 CARRIER ROLLER............................................................................................................................148 TRACK SHOE................................................................................................................................150 MAIN FRAME................................................................................................................................153 SUSPENSION................................................................................................................................155 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM...................................................................................................158 PPC CONTROL PIPING DIAGRAM................................................................................................................163 WORK EQUIPMENT CONTROL....................................................................................................................164 COOLING FAN PUMP .........................................................................................................................166 COOLING FAN MOTOR.........................................................................................................................174 HYDRAULIC TANK............................................................................................................................180 ACCUMULATOR...............................................................................................................................184 PPC LOCK VALVE............................................................................................................................185 HYDRAULIC CYLINDER........................................................................................................................186 PISTON VALVE..............................................................................................................................190 QUICK DROP VALVE..........................................................................................................................191 PPC VALVE.................................................................................................................................192 PCCS LEVER................................................................................................................................206 CONTROL VALVE.............................................................................................................................209 SELF PRESSURE REDUCING VALVE..............................................................................................................241 CYLINDER STAY.............................................................................................................................248 BLADE.....................................................................................................................................249 RIPPER....................................................................................................................................254 CAB MOUNT.................................................................................................................................256 CAB.......................................................................................................................................257 AIR CONDITIONER...........................................................................................................................259 ENGING CONTROL............................................................................................................................260 ENGING CONTROL SYSTEM ....................................................................................................................261 DECELERATION POTENTIOMETER................................................................................................................262 CRI ENGING CONTROL SYSTEM.................................................................................................................263 MONITOR SYSTEM............................................................................................................................265 MONITOR PANEL.............................................................................................................................268 SENSORS...................................................................................................................................271 PALM COMMAND CONTROL SYSTEM...............................................................................................................275 20 TESTING AND ADJUSTING......................................................................................................................277 STANDARD VALUE TABLE FOR ENGING...........................................................................................................278 STANDARD VALUE TABLE FOR CHASSIS..........................................................................................................279 TESTING AND ADJUSTING.....................................................................................................................285 TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING......................................................................................287 MEASURING ENGINE SPEED ...............................................................................................................289 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)........................................................................................292 MEASURING EXHAUST TEMPERATURE.........................................................................................................294 MEASURING EXHAUST GAS COLOR ..........................................................................................................295 ADJUSTING VALVE CLEARANCE.............................................................................................................297 MEASURING COMPRESSION PRESSURE........................................................................................................299 MEASURING BLOW-BY PRESSURE............................................................................................................301 MEASURING ENGINE OIL PRESSURE ........................................................................................................302 HANDLING OF FUEL SYSTEM DEVICES.......................................................................................................303 RELEASING RESIDUAL PRESSURE FORM FUEL SYSTEM..........................................................................................303 MEASURING FUEL PRESSURE...............................................................................................................304 BLEEDING AIR FROM FUEL CIRCUIT........................................................................................................305 REDUCED CYLINDER MODE OPERATION FOR ENGINE............................................................................................308 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.........................................................................................309 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.........................................................................309 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL.....................................................................................310 MEASURING POWER TRAIN OIL PRESSURE....................................................................................................312 ADJUSTING TRANSMISSION SPEED SENSOR...................................................................................................318 SIMPLE METHOD OF TESTING BRAKE PERFORMANCE............................................................................................319 ADJUSTING BRAKE PEDAL.................................................................................................................320 EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE..................................................................................323 ADJUSTING CLEARANCE OF IDLER..........................................................................................................326 INSPECTING WEAR OF SPROCKET...........................................................................................................327 TESTING AND ADJUSTING TRACK SHOE TENSION..............................................................................................327 TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE.............................................................................328 TESTING CONTROL CIRCUIT MAIN PRESSURE.................................................................................................331 MEASURING PPC VALVE OUTPUT PRESSURE...................................................................................................332 ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE............................................................................................334 TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLAND AND RIPPER.........................................................................335 MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER.................................................................................336 BLEEDING AIR FROM WORK EQUIPMENT CYLINDER.............................................................................................336 RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER................................................................................337 ADJUSTING SAFETY LOCK LEVER...........................................................................................................338 MEASURING FAN MOTOR SPEED.............................................................................................................339 MEASURING FAN PUMP CIRCUIT PRESSURE...................................................................................................340 BLEEDING AIR FORM FAN PUMP............................................................................................................343 ADJUSTING BLADE.......................................................................................................................344 TESTING AND ADJUSTING OF OPERATOR'S CAB...............................................................................................346 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS).............................................................................................350 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER.................................................................................387 ADJUSTMENT METHOD OF REPLACED CONTROLLER..............................................................................................387 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM..............................................................................389 PM CLINIC SERVICE.....................................................................................................................391 UNDERCARRIAGE CHECK SHEET.............................................................................................................397 TROUBLESHOOTING...........................................................................................................................400 POINTS TO REMEMBER WHEN TROUBLESHOOTING...............................................................................................401 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................402 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................403 CHECKS BEFORE TROUBLESHOOTING.........................................................................................................411 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING......................................................................................412 TYPES AND LOCATIONS OF CONNECTORS.....................................................................................................415 CONNECTOR ARRANGEMENT DRAWING.........................................................................................................421 CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)..............................................................................427 CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST・TM CIRCUIT).......................................................429 CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)..................................................................................431 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................433 T-BRANCH BOX AND T-BRANCH TABLE.......................................................................................................456 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED(ERROR CODE)..............................................................................458 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.....................................................................................461 TROUBLE CODE TABLE................................................................................................................462 ERROR CODE [1500LO] (TRANSMISSION CLUTCH:SEE THE LIST.(L1)).......................................................................463 ERROR CODE [15SAL1] (FORWARD CLUTCH:SEE THE LIST.(L1))............................................................................464 ERROR CODE [15SALH] (FORWARD CLUTCH:SEE THE LIST.(LH))............................................................................465 ERROR CODE [15SBL1] (REVERSE CLUTCH:SEE THE LIST.(L1))............................................................................466 ERROR CODE [15SBLH] (REVERSE CLUTCH:SEE THE LIST.(LH))............................................................................467 ERROR CODE [15SEL1] (1ST CLUTCH:SEE THE LIST.(L1))................................................................................468 ERROR CODE [15SELH] (1ST CLUTCH:SEE THE LIST.(LH))................................................................................469 ERROR CODE [15SFL1] (2ND CLUTCH:SEE THE LIST.(L1))................................................................................470 ERROR CODE [15SFLH] (2ND CLUTCH:SEE THE LIST.(LH))................................................................................471 ERROR CODE [15SGL1] (3RD CLUTCH:SEE THE LIST.(L1))................................................................................472 ERROR CODE [15SGLH] (3RD CLUTCH:SEE THE LIST.(LH))................................................................................473 ERROR CODE [A000N1] (ENGINE:OVERRUN (N1)).........................................................................................474 ERROR CODE [AB00MA] (ALTERNATOR:MALFUNCTION (MA)).................................................................................475 ERROR CODE [AD00L2] (COMMON RAIL:SEE THE LIST.(L2))...............................................................................475 ERROR CODE [AD00MA] (COMMON RAIL:DEFECTIVE FUNCTION(MA))..........................................................................476 ERROR CODE [AD10L3] (FUEL SUPPLY PUMP:SEE THE LIST.(L3))..........................................................................476 ERROR CODE [AD10MA] (FUEL SUPPLY PUMP:DEFECTIVE FUNCTION (MA))....................................................................479 ERROR CODE [AD10MB] (FUEL SUPPLY PUMP:FUNCTION REDUCTION (MB))....................................................................479 ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1:DISCONNECTION IN WIRING (KA))....................................................480 ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1:SHORT CIRCUIT (KB))..............................................................481 ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION IN WIRING (KA))....................................................482 ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION IN SHORT (KB)).....................................................483 ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID:DISCONNECTION IN WIRING (KA)).........................................................484 ERROR CODE [ADAZKB] (NO.1.2,AND 3 INJECTOR SOLENOIDS:SHORT(KB))...................................................................485 ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID:DISCONNECTION IN WIRING(KA))..........................................................487 ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID:DISCONNECTION IN WIRING(KA))..........................................................488 ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID:DISCONNECTION IN WIRING(KA))..........................................................489 ERROR CODE [ADDZKB] (NO.4.5,AND 6 INJECTOR SOLENOIDS:SHORT(KB))...................................................................490 ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID:DISCONNECTION(KA))...............................................................492 ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID:DISCONNECTION(KA))...............................................................493 ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)).....................................................................494 ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)).............................................................................494 ERROR CODE [B@BCZK] (RADIATOR COOLANT:LEVEL REDUCTION (ZK)).......................................................................495 ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS))...............................................................................495 ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))................................................................................496 ERROR CODE [D110KA] (BATTERY RELAY:DISCONNECTION(KA)).............................................................................497 ERROR CODE [D110KB] (BATTERY RELAY:SHORT CIRCUIT(KB)).............................................................................498 ERROR CODE [D13OKA] (NEUTRAL SAFETY RELAY: DISCONNECTION (KA))....................................................................499 ERROR CODE [D13OKB] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB))....................................................................501 ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA)).....................................................................502 ERROR CODE [D161KB] (BACK-UP ALARM RELAY:SHORT CIRCUIT (KB))......................................................................504 ERROR CODE [D182KZ] (PREHEATER RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................506 ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY : SHORT CIRCUIT (KB))..............................................508 ERROR CODE [D5ZFKA] (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA)).............................................................510 ERROR CODE [D5ZFKB] (TRANSMISSION NEUTRAL SIGNAL:SHORT CIRCUIT(KB))...............................................................511 ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)................................................512 ERROR CODE [DAQ0KK] [DB30KK] (STEERING AND TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION/INPUT (KK))...........................514 ERROR CODE [DAQ0KT] [DB30KT] (STEERING AND TRANSMISSION CONTROLLER:ABNORMALITY IN CONTROLLER(KT)).................................515 ERROR CODE [DAQ5KK] [DB35KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))....516 ERROR CODE [DAQ6KK] [DB36KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)).......518 ERROR CODE [DAQ9KQ] [DB39KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION:TYPE SELECT SIGNAL INSISTENCY (KQ)).............519 ERROR CODE [DAQRKR] [DB3RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (KR))................520 ERROR COED [DB20KQ] (ENGINE CONTROLLER TYPE COLLATION:TYPE SELECT CODE INCONSISTENCY (KQ))........................................522 ERROR CODE [DB20KT] (ENGINE CONTROLLER :ABNORMALITY IN CONTROLLER (KT))...........................................................524 ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)).....................................525 ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT:TYPE SELECT SIGNAL INCONSISTENCY (KQ)).........................................527 ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL:MALFUNCTION (MA)).............................................528 ERROR CODE [DB2RKR] (ENGINE CONTROLLER CAN COMMUNICATION :DEFECTIVE COMMUNICATION (KR))...........................................529 ERROR CODE [DB2RMC] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (MC)).........................531 ERROR CODE [DB30KK] [DAQ0KK] (STEERING AND TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION/INPUT (KK)............................533 ERROR CODE [DB30KT] [DAQ0KT] (STEERING AND TRANSMISSION CONTROLLER:ABNORMALITY IN CONTROLLER (KT).................................533 ERROR CODE [DB35KK] [DAQ5KK] (STEERING AND TRANSMISSION CONTROLLER ENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)......533 ERROR CODE [DB36KK] [DAQ6KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)....533 ERROR CODE [DB39KQ] [DAQ9KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)..........533 ERROR CODE [DB3RKR] [DAQRKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (KR).................533 ERROR CODE [DD11KB] (STARTING SWITCH:SHORT CIRCUIT (KB))..........................................................................534 ERROR CODE [DD12KA] (SHIFT UP SWITCH:DISCONNECTION (KA))..........................................................................535 ERROR CODE [DD12KB] (SHIFT UP SWITCH:SHORT CIRCUIT (KB))..........................................................................537 ERROR CODE [DD13KA] (SHIFT DOWN SWITCH:DISCONNECTION (KA))........................................................................539 ERROR CODE [DD13KB] (SHIFT DOWN SWITCH:SHORT CIRCUIT (KB))........................................................................541 ERROR CODE [DD14KA] [DDQ2KA] (PARKING LEVER SWITCH:DISCONNECTION (KA))............................................................543 ERROR CODE [DD14KB] [DDQ2KB] (PARKING LEVER SWITCH:SHORT CIRCUIT(KB)).............................................................545 ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH:REFER TO TABLE (L6))..............................................................547 ERROR CODE [DDQ2KA] [DD14KA] (PARKING LEVER SWITCH:DISCONNECTION (KA))............................................................549 ERROR CODE [DDQ2KB] [DD14KB] (PARKING LEVER SWITCH:SHORT CIRCUIT (KB))............................................................549 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))............550 ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE):SEE TABLE (L6))........................................551 ERROR CODE (DGE4KX] (FUEL TEMPERATURE SENSOR:INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))............................................552 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE(KX))...................................553 ERROR CODE [DH21KA] (HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:DISCONNECTION (KA))..........................................554 ERROR CODE [DH21KB] (HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR:SHORT CIRCUIT (KB))..........................................555 ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE(KX))......................................................556 ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE(KX))................................................558 ERROR CODE [DK10KX] (FUEL CONTROL DIAL:INPUT IS OUT OF NORMAL RANGE (KX)).........................................................560 ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER:INPUT IS OUT OF NORMAL RANGE (KX))................................................562 ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA))................................................................564 ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB))................................................................566 ERROR CODE [DK30KX] (STEERING POTENTIOMETER :INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))............................................567 ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1 : SEE THE TABLE(L8))................................................................568 ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2 : DISCONNECTION (KA))...............................................................569 ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2 : SHORT CIRCUIT (KB))...............................................................571 ERROR CODE [DK40KA] (BRAKE POTENTIOMETER : DISCONNECTION(KA)).....................................................................572 ERROR CODE [DK40KB] (BRAKE POTENTIOMETER : SHORT CIRCUIT(KB)).....................................................................574 ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).....................................575 ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ))..........................................575 ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE THE TABLE (L8))...........................................................576 ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1 :DISCONNECTION (KA)).........................................................577 ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1 :SHORT CIRCUIT (KB)).........................................................579 ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2 :DISCONNECTION (KA)).........................................................580 ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2 :SHORT CIRCUIT (KB)).........................................................582 ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR : DISCONNECTION (KA)).....................................................................583 ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR : SHORT CIRCUIT (KB)).....................................................................584 ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR :SEE TABLE (LC))......................................................................585 ERROR CODE [DLF1KA] (TRANSMISSION BEVEL SPEED SENSOR :DISCONNECTION (KA)).........................................................587 ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR :SEE THE TABLE (LC))...................................................................588 ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))..........................................................................589 ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID : DISCONNECTION (KA))...................................................................590 ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID : SHORT CIRCUIT (KB))...................................................................591 ERROR CODE [DWN1KA] (HSS EPC SOLENOID LEFT : DISCONNECTION (KA))..................................................................592 ERROR CODE [DWN1KB] (HSS EPC SOLENOID LEFT : SHORT CIRCUIT (KB))..................................................................593 ERROR CODE [DWN2KA] (HSS EPC SOLENOID RIGHT : DISCONNECTION (KA)).................................................................594 ERROR CODE [DWN2KB] (HSS EPC SOLENOID RIGHT : SHORT CIRCUIT (KB)).................................................................595 ERROR CODE [DWN5KA] (FAN PUMP SOLENOID : DISCONNECTION (KA))......................................................................596 ERROR CODE [DWN5KB] (FAN PUMP SOLENOID :SHORT CIRCUIT (KB)).......................................................................597 ERROR CODE [DXA0KA] (HSS・HYDRAULIC PUMP TVC SOLENOID: DISCONNECTION (KA)).........................................................598 ERROR CODE [DXA0KB] (HSS・ HYDRAULIC PUMP TVC SOLENOID: SHORT CIRCUIT (KB))........................................................599 ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)).........................................................................600 ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)).........................................................................601 ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)).........................................................................602 ERROR CODE [DXH5KB] (2ND CLUTCH ECMV:SHORT CIRCUIT (KB))..........................................................................603 ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)).........................................................................604 ERROR CODE [DXH6KB] (3RD CLUTCH ECMV:SHORT CIRCUIT (KB))..........................................................................605 ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA)).....................................................................606 ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV:SHORT CIRCUIT (KB))......................................................................607 ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA)).....................................................................608 ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV:SHORT CIRCUIT (KB))......................................................................609 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).........................................................................................610 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.....................................................................................611 E-1 THE ENGINE DOES NOT START.....................................................................................................612 E-2 THE PREHEATER DOES NOT OPERATE.(MANUAL PREHEATING FUNCTION)...................................................................614 E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON...............................................616 E-4 WHEN THE STARTING SWITCH IS TURNED ON,THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT........................617 E-5 WHEN THE STARTING SWITCH IS TURNED OD,THE RADIATOR WATER LEVEL CAUTION LAMP FLASHES...........................................618 E-6 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES..................................................619 E-7 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES.............................................................621 E-8 WHILE THE PREHEATER IS OPERATING , THE PREHEATING PILOT LAMP DOES NOT COME ON.................................................624 E-9 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.................................................................626 E-10 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGS IS ABNORMAL..................................................................627 E-11 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...............................................................628 E-12 INDICATION OF THE FUEL GAUGES IS ABNORMAL....................................................................................629 E-13 INDICATIONS OF GAES SPEED AND ENGINE SPEED ARE ABNORMAL......................................................................630 E-14 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL......................................................................630 E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT ..........................................................................631 E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP.............................................................................632 E-17 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED...........................................................................633 E-18 THE BUZZER CANCEL SWITCH DOES NOT WORK.......................................................................................634 E-19 THE INFORMATION SWITCH DOES NOT WORK.........................................................................................635 E-20 THE MANUAL MODE DOES NOT OPERATE OR CANNOT BE RESET..........................................................................637 E-21 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE..........................................................................638 E-22 THE BACK-UP ALARM DOES NOT SOUND.............................................................................................640 E-23 THE HEAD LAMP, REAR LAMP, AND RIPPER POINT LAMP DO NOT LIGHT UP..............................................................641 E-24 MALFUNCTION OF WIPERS........................................................................................................644 E-25 WASHING WATER DOES NOT COME OUT..............................................................................................660 E-26 THE AIR CONDITIONER DOES NOT OPERATE.........................................................................................665 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...........................................................................670 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.....................................................................................671 H-1 NO TRAVEL POWER (NO DRAWBAR PULL).............................................................................................672 H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)...................................................................................673 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE......................................................................................674 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERES...................................................................675 H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE...................................................676 H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD)......................................................................677 H-7 STEERING SPEED OR POWER IS LOW................................................................................................677 H-8 BRAKE DOES NOT WORK...........................................................................................................678 H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE.......................................................................................678 H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR................................................679 H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW...........................................................................................679 H-12 WORK EQUIPMENT DOES NOT MOVE.................................................................................................680 H-13 BLAND LIFT SPEED IS SLOW OR LACKS POWER......................................................................................680 H-14 BLAND TILT SPEED IS SLOW OR LACKS POWER......................................................................................681 H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER.....................................................................................681 H-16 EXCESSIVE HYDRAULIC DRIFT OR BLADE LIFT......................................................................................682 H-17 EXCESSIVE HYDRAULIC DRIFT OR BLADE TILT......................................................................................682 H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT.....................................................................................683 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).............................................................................................684 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................685 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).....................................................................689 S-2 ENGINE DOES NOT START.........................................................................................................690 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..........................................................................693 S-4 ENGINE STOPS DURING OPERATIONS................................................................................................694 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).....................................................................................695 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..........................................................................................696 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)................................................................................697 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE )......................................................................698 S-9 OIL BECOMES CONTAMINATED QUICKLY..............................................................................................699 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................700 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN)......................................................701 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) ..................................................................702 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)..........................................................................................703 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).............................................................................704 S-15 ABNORMAL NOISE IS MADE.......................................................................................................705 S-16 VIBRATION IS EXCESSIVE.......................................................................................................706 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................707 HOW TO READ THIS MANUAL ..................................................................................................................709 PRECAUTIONS WHEN PERFORMING OPERATION.....................................................................................................711 SPECIAL TOOL LIST.........................................................................................................................713 SKETCH OF SPECIAL TOOL....................................................................................................................717 FUEL SUPPLY PUMP..........................................................................................................................721 SPECIAL TOOLS.........................................................................................................................721 REMOVAL...............................................................................................................................721 INSTALLATION..........................................................................................................................724 FUEL INJECTOR.............................................................................................................................727 REMOVAL...............................................................................................................................727 INSTALLATION..........................................................................................................................728 NOZZLE TIP................................................................................................................................731 SPECIAL TOOL..........................................................................................................................731 REMOVAL...............................................................................................................................731 INSTALLATION..........................................................................................................................732 ENGINE FRONT SEAL.........................................................................................................................733 SPECIAL TOOLS.........................................................................................................................733 REMOVAL ..............................................................................................................................733 INSTALLATION..........................................................................................................................734 ENGINE REAR SEAL..........................................................................................................................735 SPECIAL TOOLS.........................................................................................................................735 REMOVAL AND INSTALLATION..............................................................................................................735 ENGINE CYLINDER HEAD......................................................................................................................738 SPECIAL TOOLS.........................................................................................................................738 REMOVAL...............................................................................................................................738 INSTALLATION..........................................................................................................................743 ENGINE OIL PAN............................................................................................................................746 REMOVAL...............................................................................................................................746 INSTALLATION..........................................................................................................................748 FUEL TANK.................................................................................................................................749 REMOVAL...............................................................................................................................749 INSTALLATION..........................................................................................................................750 RADIATOR..................................................................................................................................751 REMOVAL...............................................................................................................................751 INSTALLATION..........................................................................................................................752 ENGINE....................................................................................................................................753 SPECIAL TOOLS.........................................................................................................................753 REMOVAL...............................................................................................................................753 INSTALLATION..........................................................................................................................756 DAMPER....................................................................................................................................757 REMOVAL...............................................................................................................................757 INSTALLATION..........................................................................................................................758 SPECIAL TOOLS.........................................................................................................................759 DISASSEMBLY...........................................................................................................................760 ASSEMBLY..............................................................................................................................762 POWER TRAIN UNIT..........................................................................................................................764 REMOVAL...............................................................................................................................764 INSTALLATION..........................................................................................................................767 DISCONNECTION.........................................................................................................................768 CONNECTION............................................................................................................................771 TORQFLOW TRANSMISSION.....................................................................................................................772 SPECIAL TOOLS.........................................................................................................................772 DISASSEMBLY...........................................................................................................................772 ASSEMBLY..............................................................................................................................778 HSS.......................................................................................................................................786 SPECIAL TOOLS.........................................................................................................................786 DISASSEMBLY...........................................................................................................................786 ASSEMBLY..............................................................................................................................793 PTO.......................................................................................................................................804 DISASSEMBLY...........................................................................................................................804 ASSEMBLY..............................................................................................................................806 TORQUE CONVERTER..........................................................................................................................810 DISASSEMBLY...........................................................................................................................810 ASSEMBLY..............................................................................................................................811 SCAVENGING PUMP...........................................................................................................................814 REMOVAL AND INSTALLATION..............................................................................................................814 HSS AND WORK EQUIPMENT PUMP...............................................................................................................815 REMOVAL...............................................................................................................................815 INSTALLATION..........................................................................................................................816 FAN PUMP..................................................................................................................................817 REMOVAL AND INSTALLATION..............................................................................................................817 POWER TRAIN AND LUBRICATING OIL PUMP......................................................................................................818 REMOVAL AND INSTALLATION..............................................................................................................818 HSS MOTOR.................................................................................................................................819 REMOVAL AND INSTALLATION..............................................................................................................819 FINAL DRIVE...............................................................................................................................820 SPECIAL TOOLS.........................................................................................................................820 REMOVAL...............................................................................................................................820 INSTALLATION..........................................................................................................................821 SPECIAL TOOLS.........................................................................................................................822 DISASSEMBLY...........................................................................................................................822 ASSEMBLY..............................................................................................................................827 TRACK FRAME...............................................................................................................................834 REMOVAL...............................................................................................................................834 INSTALLATION..........................................................................................................................836 IDLER.....................................................................................................................................837 REMOVAL AND INSTALLATION..............................................................................................................837 SPECIAL TOOLS.........................................................................................................................839 DISASSEMBLY...........................................................................................................................839 ASSEMBLY..............................................................................................................................840 RECOIL SPRING.............................................................................................................................843 REMOVAL...............................................................................................................................843 INSTALLATION..........................................................................................................................844 SPECIAL TOOLS.........................................................................................................................845 DISASSEMBLY...........................................................................................................................845 ASSEMBLY..............................................................................................................................847 TRACK ROLLER..............................................................................................................................849 REMOVAL AND INSTALLATION..............................................................................................................849 SPECIAL TOOLS.........................................................................................................................850 DISASSEMBLY...........................................................................................................................850 ASSEMBLY..............................................................................................................................851 CARRIER ROLLER............................................................................................................................853 REMOVAL AND INSTALLATION..............................................................................................................853 SPECIAL TOOLS.........................................................................................................................854 DISASSEMBLY...........................................................................................................................854 ASSEMBLY..............................................................................................................................855 TRACK SHOE................................................................................................................................857 CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY............................................................................................857 EXPANSION TRACK SHOE ASSEMBLY (ORDINARY)..............................................................................................857 EXPANSION TRACK SHOE ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL TROUBLE).................................................................858 INSTALLATION..........................................................................................................................859 SPECIAL TOOLS.........................................................................................................................860 WHOLE DISASSEMBLY.....................................................................................................................860 WHOLE ASSEMBLY........................................................................................................................862 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS.........................................................................................873 DISASSEMBLY OF 1 LINK IN THE FIELD....................................................................................................874 DISASSEMBLY AND ASSEMBLY OF MASTER LINK...............................................................................................876 PIVOT SHAFT...............................................................................................................................879 REMOVAL AND INSTALLATION..............................................................................................................879 EQUALIZER BAR.............................................................................................................................880 REMOVAL...............................................................................................................................880 INSTALLATION..........................................................................................................................881 DISASSEMBLY AND ASSEMBLY..............................................................................................................882 WORK EQUIPMENT CONTROL VALVE..............................................................................................................884 REMOVAL...............................................................................................................................884 INSTALLATION..........................................................................................................................886 ASSEMBLY..............................................................................................................................887 HYDRAULIC CYLINDER........................................................................................................................888 SPECIAL TOOLS.........................................................................................................................888 DISASSEMBLY...........................................................................................................................888 ASSEMBLY..............................................................................................................................891 BLADE.....................................................................................................................................893 REMOVAL...............................................................................................................................893 INSTALLATION..........................................................................................................................894 RIPPER....................................................................................................................................895 DISASSEMBLY ..........................................................................................................................895 ASSEMBLY..............................................................................................................................897 ROPS GUARD................................................................................................................................899 REMOVAL AND INSTALLATION..............................................................................................................899 OPERATOR'S CAB............................................................................................................................900 REMOVAL...............................................................................................................................900 INSTALLATION..........................................................................................................................902 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)............................................................................905 SPECIAL TOOLS.........................................................................................................................906 REMOVAL...............................................................................................................................906 INSTALLATION..........................................................................................................................907 FLOOR FRAME...............................................................................................................................914 SPECIAL TOOLS.........................................................................................................................914 REMOVAL...............................................................................................................................914 INSTALLATION..........................................................................................................................917 ENGINE CONTROLLER.........................................................................................................................919 REMOVAL AND INSTALLATION..............................................................................................................919 STEERING AND TRANSMISSION CONTROLLER......................................................................................................920 REMOVAL AND INSTALLATION..............................................................................................................920 ENGINE HOOD...............................................................................................................................921 REMOVAL AND INSTALLATION..............................................................................................................921 FAN DRIVE.................................................................................................................................922 REMOVAL...............................................................................................................................922 INSTALLATION..........................................................................................................................923 FAN MOTOR.................................................................................................................................924 REMOVAL AND INSTALLATION..............................................................................................................924 90 OTHERS.....................................................................................................................................925 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................926 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3)............................................................................................927 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/3)............................................................................................928 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (3/3)............................................................................................929 ELECTRICAL CIRCUIT DIAGRAM (1/6)..........................................................................................................930 ELECTRICAL CIRCUIT DIAGRAM (2/6)..........................................................................................................931 ELECTRICAL CIRCUIT DIAGRAM (3/6)..........................................................................................................932 ELECTRICAL CIRCUIT DIAGRAM (4/6)..........................................................................................................933 ELECTRICAL CIRCUIT DIAGRAM (5/6)..........................................................................................................934 ELECTRICAL CIRCUIT DIAGRAM (6/6)..........................................................................................................935 CAB ELECTRICAL CIRCUIT DIAGRAM............................................................................................................936
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